Carnaby 125 Service Manual

SERVICE STATION MANUAL
633986 IT-633987 EN-633988 FR-633989 DE-633990

ES-633991 PT-633992 OL-633993 EL
Carnaby 125 - 200
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SERVICE STATION
MANUAL
Carnaby 125 - 200
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
Carnaby 125 - 200
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to
have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures.
Any significant changes made to the vehicle characteristics or to specific repair operations will be
promptly communicated by updates to this manual. Nevertheless, no work can be satisfactory if the
necessary equipment and tools are not available. It is therefore advisable to read the sections of this
manual relating to special tools as well as the tool catalogues.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME

INDEX OF TOPICS
CHARACTERISTICS CHAR

Carnaby 125 - 200 Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling
members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7

Characteristics Carnaby 125 - 200
Vehicle identification
The chassis prefix «A» is located near the right

shock absorber connection to the frame.
The engine prefix «B» is stamped near the left

shock absorber lower support.
VEHICLE IDENTIFICATION 125

Specification Desc./Quantity
Frame prefix ZAPM 60200
Engine prefix M28FM
VEHICLE IDENTIFICATION 200

Frame prefix ZAPM 60100
Engine prefix M601M
CHAR - 8

Dimensions and mass
WEIGHTS AND DIMENSIONS 125

Kerb weight 154 ± 5 kg
Maximum weight allowed 350 kg
Overall height 1.175 mm
Width 755 mm
Wheelbase 1.370 mm
Length 2,025 mm
WEIGHTS AND DIMENSIONS 200

Kerb weight 154 ± 5 kg
Maximum weight allowed 350 kg
Overall height 1.175 mm
Width 755 mm
Wheelbase 1.370 mm
Length 2,025 mm
Engine
ENGINE 125
Type Single-cylinder, 4-stroke
Cubic capacity 124 cm³
Bore x stroke 57.0 x 48.6 mm
Compression ratio 12 ± 0.5: 1
Engine idle speed 1650 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm
Max. Power 11 kW at 9,750 rpm
MAX. torque 12 Nm at 8,000 rpm
CHAR - 9

Lubrication Engine lubrication with lobe pump (inside crankcase) controlled
by a chain with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.
Cooling Forced-circulation coolant system.
Fuel Unleaded petrol (95 RON)
Exhaust muffler absorption-type exhaust muffler with catalytic converter.
Emission regulations EURO 3
ENGINE 200
Type Single-cylinder, 4-stroke
Cubic capacity 198 cm³
Bore x stroke 72 x 48.6 mm
Compression ratio 11 ± 0.5 : 1
Engine idle speed 1650 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm
MAX. power 14.5 kW at 9,000 rpm
MAX torque 16.5 Nm at 7.250 rpm
Lubrication Engine lubrication with lobe pump (inside crankcase) controlled
by a chain with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.
Cooling Forced-circulation coolant system.
Fuel Unleaded petrol (95 RON)
Exhaust muffler absorption-type exhaust muffler with catalytic converter.
Emission regulations EURO 3
Transmission
TRANSMISSION
Transmission Automatic expandable pulley variator with torque server, V-
belt, self-ventilating dry automatic centrifugal clutch and trans-
mission housing with forced-circulation air cooling.
Final reduction Gear reduction unit in oil bath.
Capacities
CAPACITY
Engine oil 1.10 l
Transmission oil 250 cm³
Cooling system fluid ~2l
Fuel tank (reserve) ~ 10 l (2 l)
Electrical system
ELECTRICAL SYSTEM 125

Start-up Electric
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance 10° at 2.000 rpm - 29° at 6.750 rpm
CHAR - 10

Spark plug CHAMPION RG4HC
Alternative spark plug NGK CR8EB
Battery Sealed, 12 V / 10 Ah
ELECTRICAL SYSTEM 200

Start-up Electric
Ignition Capacitive discharge ignition, with variable advance and sep-
arate HV coil.
Ignition advance 10° at 2,000 rpm - 26° at 6,750 rpm
Spark plug CHAMPION RG4HC
Alternative spark plug NGK CR8EB
Battery SEALED 12V / 12Ah BATTERY
Frame and suspensions
CHASSIS AND SUSPENSIONS

Chassis Tubular and sheet steel.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Front suspension travel 104 mm
Rear suspension Two double-acting shock absorbers with preloading adjust-
ment in 4 positions.
Rear suspension travel - mm
Brakes
BRAKES
Front brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar right lever.
Rear brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar left lever.
Wheels and tyres
WHEELS AND TYRES

Wheel rim type Light alloy rims.
Front rim 16'' x 3.00
Rear rim 16'' x 3.00
Front tyre Tubeless, 110/70 - 16'' 52P
Rear tyre Tubeless, 130/70 - 16'' 61P
Front tyre pressure (with passenger) 2 bar (2 bar)
Rear tyre pressure (with passenger) 2.2 bar (2.3 bar)
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Secondary air
The SAS for LEADER engines operates in a similar manner to the SAS for 2T engines.
The differences are the following:
CHAR - 11

instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge
pipe on the head.
The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected
to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions
in the muffler.
Air is drawn through the opening «A», goes through the first filter and is channelled through the opening
«B».
Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters
the diaphragm device, and then is channelled to the head.
CHAR - 12

The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to
supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reac-
tion of the catalytic converter.
Carburettor
125cc Version
Kehin
CARBURETTOR KEIHIN
Type Depression carburettor
Model CVK 30
Body stamping CVK
CHAR - 13

Tapered pin stamping 306D
CUT-OFF device Not present
Diffuser Ø 29
Maximum jet 98
Minimum jet 35
Max. air jet 70
Minimum air jet 130
Throttle valve spring 100 ÷ 160 g
Minimum mixture set screw initial opening 2
Tapered pin Ø 2.45
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5
Starter jet 42
Starter device resistance ~ 20 Ω
Starter pin travel 10
200cc Version
Kehin
CARBURETTOR KEIHIN
Type Depression carburettor
Model CVK 30
Body stamping CVK
Tapered pin stamping 309D
CUT-OFF device Present
Diffuser Ø 29
Maximum jet 90
Minimum jet 35
Max. air jet 70
Minimum air jet 115
Throttle valve spring 150 ÷ 250 g
Minimum mixture set screw initial opening 2½
Tapered pin Ø 2.49
Diffuser nozzle Ø 2.8
Starter air jet Ø 1.5
Starter jet 42
Starter device resistance ~ 20 Ω
Starter pin travel 10
Tightening Torques
STEERING
Name Torque in Nm
Upper steering ring nut 30 ÷ 36
Steering lower ring nut 10 ÷ 13 then loosen by 90°
Handlebar fixing screw (*) 45 ÷ 50
Fixing screws for handlebar control assembly U-bolts 7 ÷ 10
FRAME ASSEMBLY
Name Torque in Nm
Bolt of the Silent block support plate 54
Frame arm-engine arm coupling pin nut 61
Frame-swinging arm pin nut 60
Engine-swinging arm bolt 40
Centre stand bolt 25 ÷ 30
CHAR - 14

FRONT SUSPENSION
Name Torque in Nm
Fixing screw for pumping elements to lower fork plate 20 ÷ 25
Front wheel axle 45 ÷ 50
Fork leg screw 6÷7
front mudguard to plate fixing screw 4.5 ÷ 7
Fixing screw for mudguard plate to fork 9 ÷ 11
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 16 ÷ 20
Calliper to fork tightening screw 20 ÷ 25
Disc tightening screw (°) 5-6
Oil bleed screw 12 - 16
Pad fastening pin 19.6 ÷ 24.5
REAR SUSPENSION
Name Torque in Nm
Left lower shock absorber support bolt 20 ÷ 25
Upper shock absorber clamp 33 ÷ 41
Lower shock absorber clamp 33 ÷ 41
Rear wheel axle 104 ÷ 126
Fixing screw for wheel rim to hub 34 ÷ 38
Muffler support arm to engine screws (*) 20 ÷ 25
REAR BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 16 ÷ 20
Brake fluid pipe-calliper fitting 16 ÷ 20
Flexible/ rigid oil pipe coupling 9 ÷ 11
Rear disc tightening bolt 11 ÷ 13
Screw tightening calliper to the support 20 ÷ 25
Screw fixing rear brake calliper support to engine 20 ÷ 25
Pad fastening pin 20 ÷ 25
MUFFLER
Name Torque in Nm
Screw fixing manifold to muffler 15.5 ÷ 18.5
Muffler heat guard fixing screw 5-6
Exhaust fumes inlet screw 22 ÷ 26
Screw fixing muffler support arm to crankcase 33 ÷ 41
Nuts fixing muffler to support arm 27 ÷ 30
Nut fixing muffler to cylinder head 16 ÷ 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 ÷ 17
Oil filter on crankcase fitting 27 ÷ 33
Engine oil drainage plug/mesh filter 24 ÷ 30
Oil filter 4÷6
Oil pump cover screws 0.7 ÷ 0.9
Screws fixing oil pump to crankcase 5-6
Oil pump control crown screw 10 ÷ 14
Oil pump cover plate screws 4÷6
Oil sump screws 10 ÷ 14
Minimum oil pressure sensor 12 ÷ 14
CHAR - 15

CYLINDER HEAD
Name Torque in Nm
Spark plug 12 ÷ 14
Nuts fixing head to cylinder (1) (^) 9 ÷ 11 + 180°
Head fixing side screws 11 ÷ 12
Starter ground screw 7 ÷ 8.5
M5 side screw locking washers on camshaft 7 ÷ 8.5
Tappet set screw lock nut 6÷8
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 11 ÷ 15
M6 central screw locking washers on camshaft 11 ÷ 15
Timing chain tensioner support screw 11 ÷ 13
Timing chain tensioner central screw 5-6
Camshaft retention plate screw 4÷6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 ÷ 13
Clutch unit nut on driven pulley 45 ÷ 50
Drive pulley nut 75 ÷ 83
Transmission cover screws 11 ÷ 13
Driven pulley shaft nut 54 ÷ 60
Rear hub cover screws 24 ÷ 27
FLYWHEEL
Name Torque in Nm
Flywheel cover fixing screws 5-6
Stator assembly screws (°) 3÷4
Flywheel nut 52 ÷ 58
Pick-Up clamping screws 3÷4
Screw fixing freewheel to flywheel 13 ÷ 15
CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4÷6
shaft) screws
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Crankcase timing system cover screws (°) 3.5 ÷ 4.5
COOLING
Name Torque in Nm
Water pump rotor cover 3÷4
Screws for water pump rotor driving link 3÷4
Thermostat cover screws 3÷4
Bleed screw: 3
(°) Apply LOCTITE 242 medium-strength threadlock

(*) The two screws must be tightened to the prescribed torque after having done so with the rear wheel
axle nut. Safety locks: see "Pre-delivery operations".
(^) Fasten the nuts in two crossed passes.
(1) Before fitting the nuts lubricate them with engine oil
Overhaul data
CHAR - 16

Assembly clearances
Cylinder - piston assy.

200 cm³ version
COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)

Name Initials Cylinder Piston Play on fitting
Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044
Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044
Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044
Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044
COUPLING CATEGORIES (WITH CAST IRON CYLINDER)

Cylinder / piston M 72 ÷ 72.007 71.953 ÷ 71.960 0.040 - 0.054
Cylinder / piston N 72.007 ÷ 72.014 71.960 ÷ 71.967 0.040 - 0.054
Cylinder / piston O 72.014 ÷ 72.021 71.967 ÷ 71.974 0.040 - 0.054
Cylinder / piston P 72.021 ÷ 72.026 71.974 ÷ 71.981 0.040 - 0.054
125 cm³ version
CHAR - 17

COUPLING CATEGORIES
Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059
Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059
Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059
Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059
Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059
Cylinder 1st Oversize B1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059
Piston 1st Oversize C1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059
Piston 1st Oversize D1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059
Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059
Cylinder 2nd Oversize B2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059
Piston 2nd Oversize C2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059
Piston 2nd Oversize D2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059
Cylinder 3rd Oversize A3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059
Cylinder 3rd Oversize B3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059
Piston 3rd Oversize C3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059
Piston 3rd Oversize D3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059
Piston rings
125 cm³ version
CHAR - 18

ENGINE SEALING RINGS

Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 ÷ 0.30
Oil scraper ring 57 x 1 A 0.10 ÷ 0.30
Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35
ENGINE SEALING RINGS (1ST OVERSIZE)

Compression ring 1st 57.2 x 1 A 0.15 ÷ 0.30
oversize
Oil scraper ring 1st 57.2 x 1 A 0.10 ÷ 0.30
Oversize
Oil scraper ring 1st 57.2 x 2.5 A 0.15 ÷ 0.35
Oversize
ENGINE SEALING RINGS (2ND OVERSIZE)

Compression ring 2nd 57.4 x 1 A 0.15 ÷ 0.30
Oversize
Oil scraper ring 2nd 57.4 x 1 A 0.10 ÷ 0.30
Oversize
Oil scraper ring 2nd 57.4 x 2.5 A 0.15 ÷ 0.35
Oversize
ENGINE SEALING RINGS (3RD OVERSIZE)

Compression ring 3rd 57.6 x 1 A 0.15 ÷ 0.30
Oversize
Oil scraper ring 3rd 57.6 x 1 A
Oversize
Oil scraper ring 3rd 57.6 x 2.5 A 0.15 ÷ 0.35
Oversize
200 cm³ version
CHAR - 19

ENGINE SEALING RINGS

Compression ring 72x1.5 A 0.15 ÷ 0.30
Oil scraper ring 72 x 1 A 0.10 ÷ 0.40
Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40
Crankcase - crankshaft - connecting rod
CRANKSHAFT HALF-BEARINGS
Crankshaft half-bearing Category B - blue 1.973 ÷ 1.976
Crankshaft half-bearing Type C - yellow 1.976 ÷ 1.979
Crankshaft half-bearing Category E - green 1.979 ÷ 1.982
CRANKCASE - CRANKSHAFT COUPLINGS

Crankshaft category 1 - E-E
Crankcase category 1
Crankshaft category 1 - C-C
Crankshaft class 2 - C-C
Crankcase class 1
Crankshaft category 2 - B-B
CRANKSHAFT - CRANKCASE
Crankshaft Category 1 28.998 ÷ 29.004
Crankshaft Class 2 29.004 ÷ 29.010
Crankcase Category 1 32.959 ÷ 32.965
Crankcase Class 2 32.953 ÷ 32.959
CHAR - 20

Fitting clearances
Crankshaft/crankcase axial clearance (H):
0.15 ÷ 0.40 mm (when cold)
CHAR - 21

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Half-shaft, transmission 16.6 +0-0.05 A D = 0.20 - 0.50
side
Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
Slot packing system
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL-
INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
MODELS WITH FIBRE HEAD GASKET (1.1)

Name Measure A Thickness
Shimming - Cylinder 67 - Head gasket 1.1 2.20 ÷ 2.45 0.4 ± 0.05
- Base gasket 0.4
CHAR - 22


Shimming - Cylinder 67 - Head gasket 1.1 2.45 ÷ 2.70 0.6 ± 0.05
- Base gasket 0.6
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL-
INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
MODELS WITH METAL HEAD GASKET (0.3)

Shimming - Cylinder 67.8 - Head gasket 1.40 ÷ 1.65 0.4 ± 0.05
0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head gasket 1.65 ÷ 1.90 0.6 ± 0.05
0.3 - Base gasket 0.6
CHAR - 23

Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4-stroke engines
(throttle control)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
CHAR - 24

INDEX OF TOPICS
TOOLING TOOL

Tooling Carnaby 125 - 200
APPROPRIATE TOOLS
Stores code Description
020151Y Air heater
020331Y Digital multimeter
020333Y Single battery charger
020334Y Multiple battery charger
001467Y014 Pliers to extract ø 15-mm bearings
TOOL - 26

Carnaby 125 - 200 Tooling

020412Y 15 mm guide
020335Y Magnetic support for dial gauge
020565Y Flywheel lock calliper spanner
020439Y 17 mm guide
020359Y 42x47-mm adaptor
TOOL - 27


020363Y 20 mm guide
020459Y Punch for fitting bearing on steering tube
020458Y Puller for lower bearing on steering tube
005095Y Engine support
008564Y Flywheel extractor
020434Y Oil pressure control fitting
TOOL - 28


020382Y011 adapter for valve removal tool
020424Y Driven pulley roller casing fitting punch
020431Y Valve oil seal extractor
020193Y Oil pressure gauge
020306Y Punch for assembling valve seal rings
020360Y Adaptor 52 x 55 mm
TOOL - 29


020364Y 25-mm guide
020376Y Adaptor handle
020444Y Tool for fitting/ removing the driven pulley

clutch
020330Y Stroboscopic light to check timing
001467Y035 Belle for OD 47-mm bearings
TOOL - 30


020368Y driving pulley lock wrench
020319Y Immobilizer check tester
020287Y Clamp to assemble piston on cylinder
020263Y Sheath for driven pulley fitting
020262Y Crankcase splitting strip
020430Y Pin lock fitting tool
TOOL - 31


020428Y Piston position check support
020426Y Piston fitting fork
020425Y Punch for flywheel-side oil seal
020423Y driven pulley lock wrench
020414Y 28-mm guide
020393Y Piston fitting band
TOOL - 32


020382Y Valve cotters equipped with part 012 re-
moval tool
020455Y 10-mm guide
020442Y Pulley lock wrench
020440Y Water pump service tool
020329Y MityVac vacuum-operated pump
020357Y 32 x 35 mm adaptor
TOOL - 33


020409Y Multimeter adaptor - Peak voltage detec-
tion
020456Y Ø 24 mm adaptor
020332Y Digital rev counter
020074Y Support base for checking crankshaft

alignment
020055Y Wrench for steering tube ring nut
TOOL - 34


002465Y Pliers for circlips
001330Y Tool for fitting steering seats
020454Y Tool for fitting piston pin stops (200 - 250)
020622Y Transmission-side oil guard punch
020444Y011 adapter ring
020444Y009 46x55 Wrench
001467Y Extractor for bearings for holes
TOOL - 35


020244Y 15 mm diameter punch
020115Y Ø 18 punch
020271Y Tool for removing-fitting silent bloc
020627Y Flywheel lock wrench
TOOL - 36


020467Y Flywheel extractor
020626Y Driving pulley lock wrench
TOOL - 37

INDEX OF TOPICS
MAINTENANCE MAIN

Carnaby 125 - 200 Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Coolant - change
Brake fluid - change
EVERY 3,000 KM
Action
Engine oil - level check/ top-up
AFTER 1,000 KM
Action
Engine oil - replacement
Hub oil - change
Engine oil - change
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Transmissions/Levers - Lubrication
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in «Idle speed adjustment» section
AFTER 6,000 KM
Action
Engine oil - change
Hub oil level - check
Spark plug/ electrode gap - check
Air filter - clean
Oil filter -Replacement
Valve clearance - Check
Sliding blocks / variable speed rollers - check
Driving belt - checking
Coolant level - check
AT 12,000 KM AND AT 60,000 KM

Action
Spark plugs - replacement
Air filter - clean
Engine oil - change
Sliding block / variable speed rollers - change
MAIN - 39

Maintenance Carnaby 125 - 200
Action
Suspensions - check
Headlight - adjustment
Driving belt - replacement
AT 18,000 KM AND AT 54,000 KM

Action
Engine oil - change
Air filter - clean
Valve clearance - check
Sliding blocks / variable speed rollers - check
Radiator - external cleaning/ check
Fuel filter - replacement
SAS filter - Cleaning
AT 24,000 KM AND AT 48,000 KM

Action
Hub oil - change
Air filter - clean
Engine oil - change
Suspensions - check
Driving Belt - replacement
AT 30,000 KM, AT 42,000 KM AND AT 66,000 KM

Action
Air filter - clean
Variable speed rollers - check or replacement
MAIN - 40

Action
AFTER 36,000 KM
Action
Air filter - clean
Engine oil - change
Suspensions - check
AFTER 72,000 KM
Action
Hub oil - change
Air filter - clean
Engine oil - change
Suspensions - check
MAIN - 41

Carburettor
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condition.
- The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due
to wear.
- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it
is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
Checking the spark advance

- To check ignition advance, use the stroboscopic
light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to
respect the proper polarity (the arrow stamped on
the pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark
= 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works
properly and the rpm indicator can read also the
high rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error
is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 ÷ 15 KΩ in
series to HV wire).
- Remove the plastic cover from the slot on the flywheel cover.
- Operating on the flash corrector displacement of the bulb, make the reference on the flywheel cover
coincide with level on the water pump drive. Read the advance degrees indicated by the stroboscopic
light.
Characteristic
Ignition advance
10° ± 1° at 2,000 rpm
- Make sure the advance degrees match the rotation rpm.
- If failures are found, check the Pick-Up and the control unit power supply (positive-negative), replace
the control unit if necessary.
MAIN - 42

- The brand new control unit prevents that the engine rotation exceeds 2000 rpm.
- The programmed control unit allows the engine to rotate within the prescribed limits.
Specific tooling
020330Y Stroboscopic light to check timing
Spark advance variation
125 cm³ version
REVOLUTION LIMITER
Operation threshold First threshold : 10700 ±50
Second threshold : 11000 ±50
Reactivation threshold First threshold : 10600±50
Second threshold : 10900±50
Spark elimination First threshold : 1 spark on 7
Second threshold : 2 sparks on 3
200 cm³ version
REVOLUTION LIMITER
Version 200 : Operation threshold First threshold : 9900 ±50 Second threshold : 10100 ±50
Version 200 : Reactivation threshold First threshold : 9800 ±50 Second threshold: 10000 ±50
MAIN - 43

Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3
Spark plug
To remove the spark plug, proceed as follows:

- Undo the two screws « A» and remove the cover.
MAIN - 44

- Operating on both sides of the scooter, undo the

screws «B».
- Remove the inspection cover «C» by pulling it
upwards.
- Disconnect the cap «D» from the spark plug HV

wire.
- Unscrew the spark plug using the wrench sup-
plied.
- Check the conditions of the spark plug, make

sure the insulation is intact and the electrodes are
not excessively worn or sooty, check the condi-
tions of the sealing washer and measure the elec-
trode gap using the appropriate thickness gauge.
- If necessary, adjust the gap by bending the side
electrode very carefully. In case of anomaly (as
described before), replace the spark plug with an-
other one of the recommended type.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-
GINE IS COLD. CHECK AND REPLACE THE SPARK PLUG
AS INDICATED IN THE SCHEDULED MAINTENANCE TA-
BLE. USING NON-COMPLYING IGNITION CONTROL
UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRI-
BED MAY SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Spark plug
CHAMPION RG4HC
Alternative spark plug
NGK CR8EB
Electrode gap
0.7 ÷ 0.8 mm
Locking torques (N*m)
MAIN - 45

Spark plug 12 ÷ 14
When refitting, place the spark plug into the hole at the due inclination and tighten it manually all the
way down. Use the wrench only to tighten it. Once locked, insert the cap «D» on the spark plug. Refit
the covers.
Hub oil
Check
-Stand the vehicle on its centre stand on flat

ground;
- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
-Take out the dipstick checking that the oil level
reaches the dipstick lower notch; if the level is un-
der the MAX. mark, it needs to be filled with the
right amount of hub oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
The notches on the hub oil level dipstick, except
for the notch indicating the MAX level, refer to oth-
er manufacturer's models and have no specific
function for this model.
Replacement
-Remove the oil filler cap «A».

- Remove the exhaust silencer.
- Remove the rear wheel.
- Remove the brake calliper and the rear brake
disc.
MAIN - 46

- Unscrew the oil drainage plug "B" and drain out

all the oil.
- Screw the drainage plug again to the prescribed
torque and refill the hub with the recommended oil.
Recommended products
AGIP ROTRA 80W-90 rear oil hub
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Hub Oil Quantity
See the Technical Data Chapter

Hub oil drainage screw 15 ÷ 17 Nm
Air filter
- Remove the air cleaner cover after undoing the
nine fixing screws «A».
- Take out the filtering element.
N.B.
CHECK THE AIR FILTER AND, IF NECESSARY, CLEAN IT
AS INDICATED IN THE SCHEDULED MAINTENANCE TA-
BLE. THE AIR JET MUST BE DIRECTED FROM THE INSIDE
TO THE OUTSIDE OF THE FILTER (I.E. OPPOSITE TO THE
SENSE THE AIR FLOWS AT REGULAR ENGINE RUN-
NING). UPON SERVICING, REMOVE THE LOCK AND THE
RUBBER HOOD UNDER THE FILTER HOUSING AS
SHOWN IN THE FIGURE AND DRAIN ALL POSSIBLE OIL
DEPOSITS.
Cleaning
- Wash with water and car shampoo.
- Dry with short blasts of compressed air and a clean cloth.
- Soak with a 50% mixture of gasoline and oil.
- Drip dry the filtering element and then squeeze it with your hands without wringing.
- Refit the filtering element.
CAUTION
MAIN - 47

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVE
CYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN
THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
Engine oil
Replacement
Change oil as indicated in the scheduled mainte-

nance table. The engine must be emptied by drain-
ing the oil through the drainage plug «B» of the
mesh pre-filter, flywheel side. Moreover, to facili-
tate oil drainage, remove the mesh pre-filter and
loosen the cap/dipstick «A». Once all the oil has
drained through the drainage hole, unscrew and
remove the oil cartridge filter «C ». Before filling,
carry out the operations described in the "Engine
oil filter" paragraph.
Since a certain quantity of oil still remains in the
circuit, fill adding approx. 600 ÷ 650 cm³ of oil
through the cap «A». Then start up the scooter,
leave it running for a few minutes and switch it off:
After about five minutes, check the level and, if
necessary, top-up but never exceeding the MAX
level reference mark.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the require-
ments of API SL, ACEA A3, JASO MA specifica-
tions

Engine oil drainage plug 24 ÷ 30
See also
Engine
MAIN - 48

oil filter
Check
In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the
thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T
engines, the deterioration of the oil characteristics, or a certain consumption should be considered
normal, especially if during the run-in period. Consumption can particularly reflect the conditions of use
(i.e. when driving at 'full acceleration' all the time, oil consumption increases).
This operation must be carried out with the engine
cold and following the procedure below:
- Place the scooter on its centre stand and on flat
ground.
- Unscrew the cap/dipstick "A", dry it with a clean
cloth and reinsert it, screwing it all the way
down.
- Remove the cap/dipstick again and check that
the level is between the min and max reference
marks; top up, if required.
The MAX level reference mark indicates the
amount of oil in the engine. If the check is carried
out after the vehicle has been used, and therefore
with a hot engine, the level line will be lower; in
order to carry out a correct check it is necessary
to wait at least 10 minutes after the engine has
been stopped, so as to get the correct level.
Characteristic
Engine oil
1.10 l
The oil should be topped up after having checked the level and in any case by adding oil without ever
exceeding the MAX. level.
Restoring the level between the MIN and MAX reference marks requires ~ 400 cm³ of oil.
Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter
being careful to lubricate the O-ring before fitting it. Change the engine oil.
MAIN - 49

AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
Oil pressure warning light
The vehicle is equipped with a warning light «F»

on the instrument panel that lights up when the key
is turned to «ON». However, this light should
switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.
Checking the ignition timing
-Remove the 4 fixing screws and move away from

the engine the flywheel cover fitted with a water
pump and cooling manifolds.
-Rotate the flywheel until the reference matches
the crankcase operation end as shown in the figure
(TDC). Make sure that the 4V reference point on
the camshaft control pulley is aligned with the ref-
erence point on the head as shown in the second
figure. If the reference mark is opposite the indi-
cator on the head, make the crankshaft turn once
more.
-The TDC reference mark is repeated also be-
tween the flywheel cooling fan and the flywheel
cover.
To use this reference mark, remove the spark plug
and turn the engine in the opposite direction to the
normal direction using a calliper spanner applied
to the camshaft command pulley casing.
N.B.
TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
MAIN - 50

Checking the valve clearance
-To check valve clearance, centre the reference

marks of the timing system.
- Use a thickness gauge to check that the clear-
ance between the valve and the set screw corre-
sponds with the indicated values. When the valve
clearance values, intake and drainage respective-
ly, are different from the ones indicated below,
adjust them by loosening the lock nut and operate
on the register with a screwdriver as shown in the
figure.
Characteristic
Valve clearance
Inlet: 0.10 mm (when cold)
Outlet: 0.15 mm (when cold)
Cooling system
Level check
- To check the level, it is necessary to look inside

the expansion tank: a mark on the side of the filler
indicates the level required.
MAIN - 51

Top-up
Check coolant level when the engine is cold as in-

dicated in the scheduled maintenance table, fol-
lowing the steps below.
Place the scooter on its centre stand and on flat
ground.
- Undo the screw and remove the expansion tank
cap located on the scooter left side.
- Remove the expansion tank cap «A » and, if

necessary, top-up if the coolant level is near or
below the mark in the expansion tank. Coolant lev-
el must always reach the mark.
-The coolant consists of an ethylene glycol and
corrosion inhibitor based 50% de-ionised water-
antifreeze solution mix.
CAUTION
TO PREVENT THE COOLANT FROM LEAKING OUT OF
THE EXPANSION TANK WHEN THE SCOOTER IS IN USE,
DO NOT EXCEED THE LEVEL INDICATED BY THE INTER-
NAL MARK.
Braking system
Level check
The brake fluid tanks for the front and rear brakes
are located on the pumps under the handlebar
cover. Proceed as follows:
- Bring the scooter onto the centre stand and with
the handlebar centred;
- check the fluid level at the sight glass as shown
in the figure.
A certain lowering of the level is caused by wear
on the pads.
MAIN - 52

Top-up
- Remove the cover on the handlebar shown in the

photograph by undoing the screw.
- Remove the tank cap by loosening the two

screws, remove the gasket and top up using only
the liquid specified without exceeding the maxi-
mum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR

EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS,
IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID
EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF-
FICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID
MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV-
ERY TWO YEARS.
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
MAIN - 53

Headlight adjustment
Proceed as follows:
- Position the unloaded scooter, in running order
and with the tyres inflated to the prescribed pres-
sure, onto a flat surface 10 m away from a half-lit
white screen; make sure the scooter axis is per-
pendicular to the screen;
- Turn on the headlight and check that the border
of the projected light beam on the screen is not
higher than 9/10 or lower than 7/10 f the height
from the ground to the centre of vehicle headlamp;
- If this is not the case, adjust the headlight by op-
erating the screw «A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
SAS filters inspection and cleaning
- Remove the flywheel cover.

- Remove the two screws fixing the SAS valve as
shown in the figure and remove the SAS valve and
the O-ring from the support
- Remove the plastic support and the gasket as

shown in the photograph
MAIN - 54

- Check that the SAS valve plastic support is not

dented or distorted
- Check that the gasket is in good conditions
- Carefully clean the inside and outside filters. Re-
place them if damaged or abnormally distorted.
- Make sure the coupling connecting the secon-
dary air to the head is not dented, overheated or
distorted. If there is, replace it.
- Check that the metal pipe does not have any
dents
To refit, follow the removal procedure but in re-
verse order, being careful to respect the direction
of the rubber coupling connecting the SAS valve
to the discharge system
CAUTION
INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE
AND ITS SUPPORT INCREASES NOISE IN THE SAS SYS-
TEM.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE CHART.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY
AIR FILTER
MAIN - 55

INDEX OF TOPICS
TROUBLESHOOTING TROUBL

Carnaby 125 - 200 Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-
place
Excess of encrustations in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Muffler obstructed Replace
Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Automatic starter failure Check: mechanical movement, electric connection and fuel
supply, replace if required.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Transmission belt worn Replace
Inefficient automatic transmission Check the rollers, the pulley movement and make sure the
drive belt is in good conditions; replace the damaged parts and
lubricate the moveable driven pulley with specific grease.
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Overheated valves Remove the head and the valves, grind or replace the valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head assembly
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Rear wheel spins at idle
REAR WHEEL ROTATES WITH ENGINE AT IDLE

Idling rpm too high Adjust the engine idle speed.
Clutch fault Check the springs / clutch masses
Starting difficulties
DIFFICULT STARTING
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Rpm too low at start-up or engine and start-up system dam- Check the starter motor, the system and the torque limiter
aged
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Automatic starter failure Check: mechanical movement, electric connection and fuel
supply, replace if required.
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
TROUBL - 57

Troubleshooting Carnaby 125 - 200

The carburettor is dirty; fuel pump damaged Remove, wash with solvent and dry with compressed air or re-
place
Battery flat Check the charge of the battery, if there are any sulphur marks,
replace and use the new battery following the instructions
shown in the chapter
Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-
ened
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air
Fuel pump fault Check the pump control device
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Worn valve guides Check and replace the head unit if required
Worn valve oil guard Replace the valve oil guard
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Insufficient lubrication pressure
LOW LUBRICATION PRESSURE

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Faulty fuel supply Check and replace the pump, if necessary, and check the pipe
sealing
Incorrect float level Restore the level in the tank by bending on the float the thrust-
ing reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Water in the carburettor Empty the tank through the appropriate bleed nipple.
Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
Engine tends to cut-off at idle
ENGINE STOP IDLING

Incorrect timing Time the system and check the timing system components
Cut off device failure Check that the following parts work properly: valve; diaphragm;
spring; and that the air calibration elements are clean; check if
the sponge filter is clean too
Incorrect idle adjustment Adjust using the rpm indicator
Pressure too low at the end of compression Check the thermal group seals and replace worn components
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
TROUBL - 58


The starter remains on Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Excessive exhaust noise
EXCESSIVE EXHAUST NOISE

Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air device disconnec- Replace the pipe
ted or dented
Reed valve of the secondary air device does not close correctly Replace the device and the coupling
and wears out the rubber coupling between the device and the
head pipe
High fuel consumption
HIGH FUEL CONSUMPTION

Float level Restore the level in the tank by bending on the float the thrust-
ing reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Loose nozzles Check the maximum and minimum nozzles are adequately
fixed in their fittings
Fuel pump failure Check that there is no fuel in the low-pressure duct
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Engine overheating
ENGINE OVERHEAT
No coolant in the cooling circuit Restore the level
Incorrect air bleeding Repeat the operation
Thermostat remains closed Replace
Fluid leak in the radiator Replace the radiator
Coolant leaking from the cooling system Inspect the whole circuit to spot the leak.
Coolant leakage through the crankcase drainage hole Replace the pump
SAS malfunctions
ANOMALIES IN THE SECONDARY AIR DEVICE

Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air device disconnec- Replace the pipe
ted or dented
Reed valve of the secondary air device does not close correctly Replace the device and the coupling
and wears out the rubber coupling between the device and the
head pipe
TROUBL - 59

Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass contact surface with the casing is mainly in the
centre with equivalent characteristics on the three masses.
Check that the clutch casing is not scored or worn in an anom-
alous way
Insufficient braking
INSUFFICIENT BRAKING
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
BRAKES OVERHEATING
Rubber gaskets swollen or stuck Replace gaskets.
Compensation holes on the pump clogged Clean carefully and blast with compressed air
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Defective piston sliding Check calliper and replace any damaged part.
Braking vibrations or noise
VIBRATIONS OR NOISE WHEN BRAKING

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Electrical system
Battery
BATTERY
Battery This is the device in the system that requires the most frequent
attention and the most thorough maintenance. If the vehicle is
TROUBL - 60


not used for some time (1 month or more) the battery needs to
be recharged periodically. The battery runs down completely in
the course of 3 months. If the battery is fitted on a motorcycle,
be careful not to invert the connections, keeping in mind that
the black ground wire is connected to the negative terminal
while the red wire is connected to the terminal marked+.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING

Electronic ignition device failure With the key switch set to "ON", jump the contacts 1 (Blue-
Black) and 5 (Green/Red) on the control unit connector.
If by operating the turn indicator control the lights are not stead-
ily on, replace the control unit; otherwise, check the cable
harness and the switch.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities in turning the steering continue even after making the
above adjustments, check the seats on which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Excessive steering play
EXCESSIVE STEERING BACKLASH

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities in turning the steering continue even after making the
above adjustments, check the seats on which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Noisy suspension
NOISY SUSPENSION
Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disk in the
attachment to the hub and the steering tube.
TROUBL - 61

Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Seal fault or breakage Check the sealing conditions of the oil seals.
TROUBL - 62

INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system Carnaby 125 - 200
KEY
1. Electronic ignition device
2. Engine stop switch
3. Magneto flywheel - Pick-up
4. Voltage regulator
5. Fuse unit
6. Automatic starter
7. Key switch
8. Stop light remote control
9. Stop button on front brake
10. Stop button on rear brake
11. Battery
12. Starter motor
13. Start-up remote control
14. Starter button
15. Wiring for antitheft device
16. Light switch
17. Headlight remote control
18. Licence plate lamp
19. Rear left turn indicator light
ELE SYS - 64

Carnaby 125 - 200 Electrical system
20. Rear light

A. Tail light bulbs
B. Stop light bulbs
21. Rear right turn indicator light
22. Front left turn indicator light
23. Headlight
A. Tail light bulbs
B. High-beam light bulb
C. Low-beam light bulb
24. Front right turn indicator light
25. Engine oil pressure sensor
26. Thermistor
27. Instrument panel
A. Instrument panel lighting bulbs
B. Speedometer
C. Clock
D. Engine disabled warning light
E. Right turn indicator warning light
F. High-beam warning light
G. Fuel gauge
H. Low fuel warning light
I. Left turn indicator warning light
L. Oil warning light
M. Water temperature gauge
28. Fuel level transmitter
29. Horn
30. Horn button
31. Thermoswitch
32. Electric fan
33. Turn signal switch
34. Electric fuel pump
35. Electric pump control device
36. Spark plug
37. HV coil
VERSIONE CON TELERUTTORE DI INIBIZIONE AVVIAMENTO
ELE SYS - 65

LEGENDA
1. Dispositivo di accensione elettronica
2. Deviatore arresto motore
3. Volano magnete - Pick-up
4. Regolatore di tensione
5. Gruppo fusibili
6. Starter automatico
7. Commutatore a chiave
8. Teleruttore luci stop
9. Pulsante di stop sul freno anteriore
10. Pulsante di stop sul freno posteriore
11. Teleruttore inibizione avviamento
12. Batteria
13. Motorino di avviamento
14. Teleruttore di avviamento
15. Pulsante di avviamento
16. Predisposizione antifurto
17. Deviatore luci
18. Teleruttore proiettore
19. Fanalino illuminazione targa
ELE SYS - 66

20. Lampeggiatore posteriore sinistro

21. Fanale posteriore
A. Lampade luce di posizione
B. Lampade luce di stop
22. Lampeggiatore posteriore destro
23. Lampeggiatore anteriore sinistro
24. Proiettore
B. Lampada luce abbagliante
C. Lampada luce anabbagliante
25. Lampeggiatore anteriore destro
26. Sensore pressione olio motore
27. Termistore
28. Gruppo strumenti
A. Lampade illuminazione strumento
B. Tachimetro
C. Orologio
D. Spia motore non abilitato
E. Spia freccia destra
F. Spia luce abbagliante
G. Indicatore livello carburante
H. Spia riserva
I. Spia freccia sinistra
L. Spia olio
M. Indicatore temperatura acqua
29. Trasmettitore livello carburante
30. Clacson
31. Pulsante clacson
32. Termointerruttore
33. Elettroventola
34. Commutatore lampeggiatori
35. Pompa elettrica carburante
36. Dispositivo comando pompa elettrica
37. Candela
38. Bobina A.T.
ELE SYS - 67

Components arrangement
ELE SYS - 68

KEY
1. Battery
2. Fuses
3. Spark plug
4. Coil
5. Pick-up
7. Control unit
8. Electric fan
9. Thermoswitch
10. Thermistor
11. Starter
ELE SYS - 69

1.Battery - 2. Fuse terminal block: To get access

to these components, unscrew the flap on the foot-
rest and reach the battery compartment.
3. Spark plug - 4. Coil: Remove the inspection

cover to reach the spark plug and the coil.
5. Pick-up: To get access to the pick-up, operate

from the right side.
6. Voltage regulator: To get access to the voltage

regulator, remove the lower part of the wheel hous-
ing.
ELE SYS - 70

7. Control unit: To get access to the control unit,

remove the shield back plate.
8. Electric fan - 9. Thermoswitch: To get access

to the electric fan, remove the front shield.
10. Thermistor: To get access to the thermistor,

remove the helmet compartment.
11. Starter: To get access to the starter, remove

the helmet compartment.
ELE SYS - 71

12. Clacson - 13. Dispositivo di comando pom-

pa elettrica carburante: Per accedervi rimuovere
il controscudo. I componenti sono situati nella
parte bassa del veicolo.
14. Teleruttori - 15. Pompa carburante: Per ac-

cedere a questi componenti rimuovere la fiancata
laterale destra.
Conceptual diagrams
Ignition
ELE SYS - 72

KEY
5. Fuse unit
7. Key switch
11. Battery
36. Spark plug
37. HV coil
LEGENDA
5. Gruppo fusibili
12. Batteria
37. Candela
38. Bobina A.T.
ELE SYS - 73

Headlights and automatic starter section
KEY
5. Fuse unit
6. Automatic starter
7. Key switch
11. Battery
16. Light switch
17. Headlight remote control
18. Licence plate lamp
20. Rear light
A. Tail light bulbs
23. Headlight
A. Tail light bulbs
B. High-beam light bulb
C. Low-beam light bulb
A. Instrument panel bulbs
ELE SYS - 74

F. High-beam warning light
LEGENDA
5. Gruppo fusibili
6. Starter automatico
12. Batteria
17. Deviatore luci
18. Teleruttore proiettore
19. Fanalino illuminazione targa
24. Proiettore
B. Lampada luce abbagliante
C. Lampada luce anabbagliante
A. Lampade illuminazione strumento
ELE SYS - 75

F. Spia luce abbagliante
Battery recharge and starting
KEY
3. Magneto flywheel - Pick-up
5. Fuse unit
7. Key switch
8. Stop light remote control
9. Stop button on front brake
10. Stop button on rear brake
11. Battery
12. Starter motor
13. Start-up remote control
14. Starter button
20. Rear light
B. Stop light bulbs
ELE SYS - 76

LEGENDA
4. Regolatore di tensione
5. Gruppo fusibili
8. Teleruttore luci stop
9. Pulsante di stop sul freno anteriore
10. Pulsante di stop sul freno posteriore
11. Teleruttore inibizione avviamento
12. Batteria
13. Motorino di avviamento
14. Teleruttore di avviamento
15. Pulsante di avviamento
B. Lampade luce di stop
D. Spia motore non abilitato
ELE SYS - 77

Level indicators and enable signals section
KEY
5. Fuse unit
7. Key switch
11. Battery
25. Engine oil pressure sensor
26. Thermistor
G. Fuel level indicator
H. Low fuel warning light
L. Oil warning light
M. Water temperature gauge
28. Fuel level transmitter
ELE SYS - 78

LEGENDA
5. Gruppo fusibili
12. Batteria
26. Sensore pressione olio motore
27. Termistore
G. Indicatore livello carburante
H. Spia riserva
L. Spia olio
M. Indicatore temperatura acqua
29. Trasmettitore livello carburante
ELE SYS - 79

Devices and accessories
KEY
5. Fuse unit
7. Key switch
11. Battery
15. Wiring for antitheft device
19. Rear left turn indicator light
21. Rear right turn indicator light
22. Front left turn indicator light
24. Front right turn indicator light
C. Clock
E. Right arrow warning light
I. Left arrow warning light
29. Horn
30. Horn button
31. Thermoswitch
ELE SYS - 80

32. Electric fan

33. Turn signal switch
34. Electric fuel pump
35. Electric pump control device
LEGENDA
5. Gruppo fusibili
12. Batteria
16. Predisposizione antifurto
20. Lampeggiatore posteriore sinistro
22. Lampeggiatore posteriore destro
23. Lampeggiatore anteriore sinistro
25. Lampeggiatore anteriore destro
C. Orologio
E. Spia freccia destra
I. Spia freccia sinistra
30. Clacson
ELE SYS - 81

31. Pulsante clacson

32. Termointerruttore
33. Elettroventola
34. Commutatore lampeggiatori
35. Pompa elettrica carburante
36. Dispositivo comando pompa elettrica
Checks and inspections
Ignition circuit
No spark plug
Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,
follow this procedure:
- Pick-Up check.
Disconnect the control unit connector and check
the resistance value between terminal No. 6
(Green) and terminal No. 8 (Black). Check the
Pick-Up and its power line:
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine
manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable har-
ness.
In case conforming values are measured, try replacing the control unit (without programming) and make
sure the failure has been solved by checking sparks are produced in the spark plug; only then program
the control unit.
ELE SYS - 82

- HV primary coil check

Disconnect the control unit connector and check
that the cable between terminal No. 3 and terminal
No. 8 is not interrupted (see figure).
If non-conforming values are measured, check
again the HV primary coil directly on the positive
and negative terminals. If non-conforming values
are measured, repair the cable harness or else re-
place the HV coil.
High voltage coil primary check
0.21 ± 0.025 Ohm
HV coil secondary check

Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see
figure).
If non-conforming values are measured, replace
the HV coil. To carry out a more complete diagno-
sis, check the peak voltage with the multimeter
adaptor.
Specific tooling
020409Y Multimeter adaptor - Peak voltage de-
tection
High voltage coil secondary resistance value
3100±310 Ohm
ELE SYS - 83

Pick-Up.
- Disconnect the control unit connector and con-
nect the positive terminal to connector No. 6 and
the negative terminal to connector No. 8 (see fig-
ure).
- The multimeter end of a scale should be 200V.
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
- Replace the Pick-Up if non-conforming values
are measured.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Voltage value
> 5 Volt
H.V. coil
With the control unit and HV coil connected, meas-
ure the voltage of the coil primary during the start-
up test with the voltage peak adaptor and con-
necting the positive terminal to the ground one and
the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE
HV COIL PRIMARY IS BLACK AND THE NEGATIVE TER-
MINAL ONE IS GREEN.
Specific tooling
020409Y Multimeter adaptor - Peak voltage de-
tection
High voltage coil voltage value
>200V
ELE SYS - 84

Stator check
Disconnect the connector from the voltage regu-

lator and check there is continuity between any
yellow cable and the other two cables.
Ohm value:
0.7 ÷ 0.9 Ohm
Also check that all yellow cables are insulated from

the ground connection.
If non-conforming values are detected, repeat the
checks directly to the stator. In case of further rep-
etitions of incorrect values replace the stator or
repair the wiring.
Voltage regulator check
With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
ELE SYS - 85

Recharge system voltage check
The recharge system is provided with a three

phase alternator with permanent flywheel.
The alternator is directly connected to the voltage
regulator.
In turn, the latter is directly connected to earth and
to the battery positive terminal passing through the
15A protection fuse (No. 1).
This system therefore requires no connection to
the key switch.
The three- phase generator provides good re-
charge power and at low revs a good compromise
is achieved between generated power and idle
stability. For this reason, it is very important that
the idle speed is adjusted as prescribed.
Connect an ammeter induction clamp to the volt-
age regulator positive terminal, measure the bat-
tery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current gen-
erated by the system with lights on and a high
running engine.
In case the generated current value is lower than
10A, repeat the test using a new regulator and/
stator alternatively.
Choke Inspection
Refer to the engine section to check the resistance

and operating conditions of the component. As re-
gards voltage supply, keep the connector connec-
ted to the system and check that the two terminals
receive battery voltage with the engine on (see
figure).
ELE SYS - 86

If no voltage is detected, connect the multimeter

negative lead to the ground connection and the
positive lead to the automatic starter White-Black
cable; with the key switch set to «ON» check
whether there is battery voltage; if there is no volt-
age, check the cable harness connections to the
key switch and make sure the 15A fuse (No. 1) is
in working order.
If there is voltage, check again the ignition control
unit connector.
After disconnecting the starter, start up the engine
and keep it at idle speed; then check whether there
is voltage connecting the multimeter positive lead
to terminal No. 5 (Green-Red), and the negative
one to terminal No. 7 (White-Black) (see figure).
If there is no voltage, replace the control unit after
making sure that the fuses are not blown; other-
wise, check the cable harness between the starter
and the control unit and, as a last resource, re-
place the starter.
Turn signals system check
- If the turn indicators do not work, proceed as fol-

lows:
- Repeat the check between terminal No. 5
(Green-Red) and terminal No. 8 (Black) with the
key switch set to «ON», the side stand up and the
emergency switch set to «RUN».
ELE SYS - 87

If no voltage is detected, check the cable harness,

the connections and make sure the 15A main fuse
(No. 1) is in working order; otherwise, proceed as
follows:
- Jump terminals No. 1 (Blue-Black) and No. 5
(Green-Red) (see figure) and activate the turn in-
dicator switch alternately to the right and left. Make
sure the lights turn on.
If they do, replace the control unit because it is
faulty. If they do not turn on, check the control unit-
turn indicator switch connection cable harness;
then, repeat the test.
If the cable harness is in good conditions and the
turn indicators still do not turn on, replace the turn
indicator switch because it is faulty.
Lights list
LIGHT BULB TABLE

1 High-beam light bulb Type: HALOGEN (H11)
Power: 12V - 55W
Quantity: 1
2 Low-beam bulb Type: HALOGEN (H11)
Power: 12V - 55W
Quantity: 1
3 Front tail light bulb Type: ALL GLASS
Power: 12V - 5W
Quantity: 2
4 Instrument panel bulb Type: ALL GLASS
Power: 12V - 1.2W
Quantity: 5
5 Front turn indicator bulb Type: SPHERICAL
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
6 Rear turn indicator bulb Type: SPHERICAL
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
7 Twin-filament stop/tail light bulb Type: SPHERICAL
Power: 12V - 5/21W
Quantity:1
8 License plate light bulb Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
ELE SYS - 88

Fuses
The electrical system has six protection fuses. To reach the board of fuses, unscrew the two screws
«A» and remove the battery cover «B».
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO
BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF
ELECTRIC WIRE).
FUSE TABLE
Fuse No. 1 Capacity:15A
Protected circuits:Electric fan, Battery recharge circuit, Elec-
tronic ignition device, Clock, Electronic ignition device, Wiring
for antitheft device, Lines protected by fuses 4.5 and 6.
Protected circuits:Headlight Remote control.
Fuse No. 3 Capacity:7.5 A
ELE SYS - 89

Protected circuits:Start-up circuit, Stop light remote control.
Protected circuits:Instrument panel gauges and warning
lights, Horn, Light switch, Headlight remote control, Wiring for
anti-theft device.
Protected circuits:Electric pump control device.
Fuse No. 6 Capacity: 5A
Protected circuits:Front tail light, Rear tail light, Instrument
panel lighting, License plate light.
Protected circuits:Free.
Protected circuits:Free.
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
- Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED
SHORTENS THE LIFE OF THE BATTERY.
IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS
TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE
COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE,
ELE SYS - 90

BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE
GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL
WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL
MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS
OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
Normal bench charging must be carried out using the specific battery charger 020333Y (single) or
020334 (multiple), setting the battery charge selector to the type of battery that needs recharging (i.e.,
at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must
be implemented by connecting corresponding poles (+ to + and - to - ).
Pump electrics check
If the engine does not work properly, the electric

pump control unit may not work properly either. In
this case:
- Remove the footrest in order to reach the electric
fuel pump.
- Disconnect the fuel supply connector from the
pump.
- Check that the fuel supply to the pump is ade-
quate according to the data on the table.
PUMP SUPPLY
Key set to «KEY ON» Supply to the pump for 13 seconds
Engine revs from 0 to 200 rpm Always «OFF»
Engine revs from 200 to 1200 rpm Always «ON»
Engine revs from 1200 to 2000 rpm 0.2 seconds «ON»
9 seconds «OFF»
Engine rpm ] 2000 rpm Always «ON»
If the pump does not work:

- Disconnect the fuel supply connector from the pump.
- Make sure there is battery voltage at the connector ends.
- If there is no voltage, check the continuity of the cable harness and replace it if damaged.
- If the cable harness is intact, check that the fuel pump works properly by applying a 12 V voltage.
Replace the pump if damaged.
- If the pump works properly, replace the control unit.
ELE SYS - 91

Smontaggio
- Remove the helmet compartment.

- Remove the side spoiler.
- Empty the cooling circuit.
- Remove the cover, disconnect the electrical ter-
minal and unscrew the thermistor.
Verifica
LEGEND:
5. Fuse unit
7. Key switch
11. Battery
26. Thermistor
ELE SYS - 92

- Connect a tester «10» (set as ohmmeter) to the

thermistor «2» as shown in the figure.
- Immerse the thermistor in a container «11» with
coolant.
In the same container, immerse a thermometer
«12» with a temperature range of 0°÷150° (32°
÷302°F).
- Place the container on a stove «13» and warm
up the coolant slowly.
- Check the temperature indicated on the ther-
mometer and the thermistor value indicated on the
tester.
- Make sure the thermistor varies according to
temperature as indicated.
COOLANT TEMPERATURE °C (°F) / RESISTANCE VALUES (OHM)

115° (239°) Approx. 26 ÷ 10
50° (122°) Approx. 205 ÷ 50
CAUTION
IF THE VALUES DO NOT VARY OR DIFFER TOO MUCH FROM THOSE INDICATED IN THE TABLE,
REPLACE THE THERMISTOR.
Montaggio
- Carry out removal operations in reverse order.

- Fill and bleed the cooling system.
ELE SYS - 93

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Carnaby 125 - 200 Engine from vehicle
Exhaust assy. Removal
- Undo the two exhaust manifold fixings on the

head.
- Undo the three screws fixing the muffler to the

support arm.
- Remove the full muffler unit.
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

Nuts fixing muffler to support arm 27 ÷ 30 Nut fixing muffler to cylinder head 16 ÷ 18
Removal of the engine from the vehicle

WARNING
IN CASE OF OPERATIONS OVERLAPPING IN THE CROSS-REFERENCES TO OTHER CHAP-
TERS, INTERPRET THESE OPERATIONS LOGICALLY, THUS AVOIDING THE UNNECESSARY
REMOVAL OF COMPONENTS.
WARNING
CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.
To remove the engine from the frame, proceed as
follows:
- Disconnect the battery.
- Remove the lower spoiler.
Remove the full muffler unit.
- Remove the rear brake calliper and release the
pipe from the clamps in the engine lower section.
ENG VE - 95

Engine from vehicle Carnaby 125 - 200
- Empty the cooling system.

- From the helmet compartment, disconnect the
coolant return pipe «A» from the water tempera-
ture thermostat. Disconnect the water temperature
sensor «B».
- Disconnect the cable «C» and the ground lead

«D» from the starter motor, disconnect the pick-up
«E» and release the cables from the clamp «F».
- Loosen the nut «G», release the throttle control

transmission from the carburettor and release the
cable harness.
- Disconnect the fuel delivery pipe «H» from the

carburettor.
ENG VE - 96

Carnaby 125 - 200 Engine from vehicle
- From the scooter left side, disconnect the con-

nector from the carburettor starter.
- From the scooter right side, disconnect the spark

plug.
- From the scooter left side, undo and remove the

engine ground screw «I»
WARNING
GET A HOIST AND BELTS TO LIFT IT.
- Place the belts on the rear part of the frame. Lift the hoist arm until the belts are tightened.
- Undo and remove the left shock absorber fixing

screw «L»
ENG VE - 97

Engine from vehicle Carnaby 125 - 200
- Undo and remove the nut fixing the engine on the

swinging arm «M»
- Slide off the engine pin on the swinging arm

«N». Remove the engine together with the centre
stand.
To refit the engine on the frame, carry out removal operations in reverse order, checking:
- Tightening torques (see the TORQUES table in the CHARACTERISTICS chapter).
- Secure the pipes and the cables with the corresponding clamps.
- Make sure the throttle control transmission is in working order.
- Make sure the electrical devices are in working order.
ENG VE - 98

INDEX OF TOPICS
ENGINE ENG

Engine Carnaby 125 - 200
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a
screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven
pulley shaft locking nut and washer.
Specific tooling
- Remove the cap/dipstick from the engine oil filling

hole.
- Remove the ten screws.
- Remove the transmission cover.
If this operation is carried out directly on the vehi-
cle, remove the cooling air supply coupling of the
transmission housing.
Air duct
- Remove the five screws on two different levels as well as the small casing.
ENG - 100

Carnaby 125 - 200 Engine
Version 125
- Remove the 4 screws and the housing.
- To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in
the figure.
Air duct filter
To remove the intake throat on the transmission

cover, remove the 2 fixing screws indicated in the
figure.
ENG - 101

Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by
means of:
Specific tooling
020412Y 15 mm guide
Refitting the driven pulley shaft bearing
- Slightly heat the crankcase from the inside so as

not to damage the painted surface.
- Insert the bearing in its seat.
- Refit the seeger ring.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAM-
AGING THE COVER PAINT.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020412Y 15 mm guide
Baffle roller
Removal
Belt support roller (200 cm³ models only)

- Check that the roller does not show signs of wear
and that it turns freely.
- Remove the special fixing screw and the roller
together with the bearing.
ENG - 102

Refitting
- Heat the roller and insert the bearing using the

specific punch:
Specific tools:
Specific tooling
020455Y 10-mm guide
- Refit the roller with the special screw.

- Tighten to the specified torque.
- Refit the intake throat with the O-ring, the sump
sealing gasket and a the fan housing.

Anti-flapping roller 12 - 16
- Heat the roller and insert the bearing using the

specific punch:
Specific tools:
Specific tooling
020455Y 10-mm guide
- Refit the roller with the special screw.

- Tighten to the specified torque.
- Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.

Anti-flapping roller 12 - 16
ENG - 103

Removing the driven pulley
- Remove the spacer, the clutch bell and the whole

driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
ENG - 104

Removing the clutch
Clutch removal (125 cm³ H2O)

Fit the driven pulley spring compressor specific
tool with medium length pins screwed in position
F from the tool internal side.
- Insert the adapter ring 8 in the pins.
- Assemble the driven pulley unit on the tool intro-
ducing the rivets heads in the adapter ring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component n°9 to
remove the nut fixing the clutch in place.
- Separate the driven pulley components (Clutch,
fan and spring with plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench
- Fit the special driven pulley spring compressor

tool with the medium-length pins in position "C"
screwed up from the inner side of the tool.
- Introduce the adapter ring 11 with the chamfering
facing the inside of the tool.
- Fit the driven pulley unit on the tool with the in-
sertion of the 3 pins in the ventilation holes in the
mass holder support.
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component 9 to
remove the nut fixing the clutch in place.
- Separate the driven pulley into its components
(Clutch and spring with its plastic holder)
ENG - 105

CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-
ENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Simultaneously turn and pull the collar manually

to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN
TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER
THE O-RING SEAL.
ENG - 106

Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.
- Remove the retaining ring using two flat blade
screwdrivers.
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Support the pulley properly using the bell as

shown in the figure.
Specific tooling
001467Y035 Belle for OD 47-mm bearings
- Remove the roller bearing using the modular punch.
Specific tooling
020363Y 20 mm guide
Inspecting the driven fixed half-pulley
- Remove the spacer, the clutch bell and the whole driven pulley unit.
ENG - 107

N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
- Measure the outer diameter of the pulley bushing.

- Check the contact surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.
Characteristic
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm
Version 125
- Measure the outer diameter of the pulley bushing.
- Check the contact surface with the belt to make
sure there are no flaws.
Characteristic
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
ENG - 108

Inspecting the driven sliding half-pulley
125 - 200 version

- Remove the two internal grommets and the two
O-rings.
- Measure the movable half-pulley bushing inside
diameter.
Characteristic
Movable driven half-pulley max. diameter
Max. diameter admitted: Ø 41.08 mm
Movable driven half-pulley standard diameter
Standard diameter: Ø 41.000 ÷ 41.035 mm
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative guide pads.
Refitting the driven half-pulley bearing
- Support the pulley bushing adequately from the

threaded side using a wooden surface.
- Fit a new roller sleeve as in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the snap ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELD
Specific tooling
020424Y Driven pulley roller casing fitting
punch
ENG - 109

Refitting the driven pulley
Driven pulley fitting

- Insert the new oil guards and O-rings on the mov-
able half-pulley.
- Lightly grease the O-rings (A) shown in the figure.
- Fit the half-pulley over the bushing using the ap-
propriate tool
Check that the pins are not worn and proceed with
the refitting in the relative hollows.-
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 gr. of
grease. Apply the grease through one of the holes
in the bushing until it comes out through the hole
on the opposite side. This operation is necessary
to avoid the presence of grease beyond the O-
rings.
N.B.
THE TORQUE SERVER CAN BE GREASED WHETHER
WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Sheath for driven pulley fitting
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
ENG - 110

- Insert the new oil guards and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
Inspecting the clutch spring
- Misurare la lunghezza libera della molla della

semipuleggia condotta mobile.
Characteristic
Standard length (125)
106 mm
limit after use (125)
101 mm
Lunghezza standard (200)
123 mm
Limite dopo l'uso (200)
118 mm
Refitting the clutch
Version 125
- Support the driven pulley spring compressor ap-
propriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position «F» on the inside.
- Preassemble the cooling fan to the clutch in such
a way that the keying facets are aligned and the 3
pin heads (A) of the mass axis can be seen in full.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
ENG - 111

- Insert the spring with its plastic holder in contact

with the clutch.
- Insert the driving belt into the pulley unit accord-
ing to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch lock nut and tighten it to the
specified torque using the specific 46x55 spanner.
- Loosen the tool clamp and insert the belt accord-
ing to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action until it reaches the pul-
leys maximum opening and place the belt on the
minimum rolling diameter.
- Remove the driven pulley /belt unit from the tool.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH
OPERATION.
Specific tooling
020444Y009 46x55 Wrench

ENG - 112

Version 125
screwed in position «F» on the inside.
- Preassemble the cooling fan to the clutch in such
a way that the keying facets are aligned and the 3
pin heads (A) of the mass axis can be seen in full.
with the clutch.
clutch nut.
- Apply the clutch lock nut and tighten it to the
specified torque using the specific 46x55 spanner.
tool.
rotation combined action until it reaches the pul-
leys maximum opening and place the belt on the
minimum rolling diameter.
N.B.
ENG - 113

N.B.
N.B.
AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH
OPERATION.
Specific tooling
020444Y009 46x55 Wrench


screwed in position "C" on the inside.
- Introduce the adapter ring 11 with the chamfering
facing upwards.
with the clutch.
clutch nut.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
tool.
ENG - 114


rotation combined action and place the belt in the
smaller diameter rolling position.
N.B.
N.B.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y009 46x55 Wrench

Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
Drive-belt
During the wear checks foreseen in the scheduled

maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
ENG - 115

Removing the driving pulley
- Preassemble the movable half-pulley with the

roller contrast plate by putting the rollers in their
housings with the larger support surface touching
the pulley according to the direction of rotation. -
Make sure the roller contact plate is not flawed or
damaged on the grooved edge. - Fit the unit to-
gether with the bushing on the crankshaft - Fit the
driven pulley/Clutch/belt unit on the engine.
- Remove the belt and slide the movable half-pul-

ley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
ENG - 116

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure the pulley sliding bushing outside di-
ameter shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
roller (200): Minimum diameter allowed
Ø 20 mm
roller (125): Minimum diameter allowed
Ø 18.5 mm
Sliding bushing: Minimum admissible diame-
ter
Ø 25.95 mm
Movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø 26.12 mm
roller (200): Standard Diameter
Diameter 20.5 - 20.7 mm
roller (125): Standard Diameter
Ø 18.9 ÷ 19.1 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
ENG - 117

Driving pulley removal

- With the appropriate tool placed into the internal
slots, remove the nut with the built-in Belleville
washer.
Appropriate tools:
Specific tooling
020442Y Pulley lock wrench
- Remove the entire start-up crown unit with the

torque limiter.
- Remove the fixed driving half-pulley together with
the O-ring and the steel washer touching the bush-
ing.
Driving pulley removal (125)

- With the appropriate tool, remove the nut with the
built-in Belleville washer, the drive common to the
kick-starter version, and the steel washer.
- Remove the fixed driving half-pulley.
- Remove the steel washer separating from the
bushing.
Appropriate tools:
Specific tooling
ENG - 118

Refitting the driving pulley
- Correctly refit the previously removed Bendix

back to its position.
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread Loctite 243 Quick Set threadlock on the
thread and tighten the nut to the prescribed torque.
- Avoid the half-pulley rotation with the appropriate
stop key tool..
- Rotate the engine manually until the belt is slight-
ly taut.
CAUTION
IT IS EXTREMELY IMPORTANT THAT THE BELT IS PER-
FECTLY FREE WHEN THE FIXED DRIVING HALF-PULLEY
IS ASSEMBLED. THIS IS TO AVOID CARRYING OUT A
WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
Specific tooling

Drive pulley nut 75 ÷ 83
ENG - 119

- Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings
with the larger support surface touching the pulley according to the direction of rotation.
- Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.
- Mount the complete bushing unit on the driving shaft.
- Fit the driven pulley/Clutch/belt unit on the engine.
Refitting the transmission cover
- Check the presence of the 2 centring dowels and

the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the
specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling

Transmission cover screws 11 ÷ 13 Driven pul-
ley shaft nut 54 ÷ 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the
figure.
- Remove the hub cover and its gasket.
ENG - 120

Removing the wheel axle
- Remove the wheel axis complete with gear.

- Remove the intermediate gear.
Removing the hub bearings
- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-
tected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
ENG - 121

Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox

cover.
- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil
guard as in the figure.
Specific tooling
020477Y Adaptor 37 mm
020483Y 30 mm guide
020489Y Hub cover support stud bolt set
Removing the driven pulley shaft bearing
- As you need to remove the driven pulley shaft, its

bearing and oil guard, remove the transmission
cover as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, work-
ing from inside the bearing and being careful not
to damage the housing, make it come out of the
belt transmission side.
- Remove the seeger ring shown in the figure
Remove the driven pulley shaft bearing using the
modular punch.
Specific tooling
020363Y 20 mm guide
ENG - 122

Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged com-
ponents.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of anomalies, replace the damaged components.
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the seeger ring.
- Fit the oil guard with seal lip towards the inside
of the hub and place it flush with the internal sur-
face by means of the appropriate tool used from
the 52 mm side.
The 52 mm side of the adapter must be turned to-
wards the bearing.
Specific tooling
020483Y 30 mm guide
ENG - 123

Refitting the hub cover bearings
- To fit the hub housing bearings, the engine crank-

case and the cover must be heated with the spe-
cial heat gun.
- The three 15 mm bearings must be fitted using
the appropriate tools.
The 42 mm side of the adapter must be turned to-
wards the bearing.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
- Refit the Seeger ring with the opening facing the
bearing and the new oil guard flush with the crank-
case on the pulley side.
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE
COVER WITH THE STUD BOLT SET.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANK-
CASE, SUPPORT THE CRANKCASE PREFERABLY ON A
SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN
VERTICALLY.
Specific tooling
020150Y Air heater support
020151Y Air heater
020412Y 15 mm guide
ENG - 124

020363Y 20 mm guide
Refitting the hub bearings
- Install the three shafts in the engine crankcase as shown in the figure.
Refitting the ub cover
- Fit a new gasket together with the centring dowels.

- Seal the gasket of the breather pipe using black silicone sealant.
- Fit the gearbox cover, making sure the breather pipe is in the correct position.
- Place the 3 shortest screws, identifiable by their different colour, as shown in the figure.
- Fasten the breather pipe support bracket with the lower short screw.
- Assemble the remaining 4 screws and tighten the 7 screws to the prescribed torque.

Rear hub cover screws 24 ÷ 27
ENG - 125

Flywheel cover
- Remove the two clamps, the two couplings and

empty the cooling system.
- Remove the 4 retainers and the flywheel cover.
Removing the hub cover
- Remove the two clamps, the two couplings and

empty the cooling system.
- Remove the 4 retainers and the flywheel cover
ENG - 126

Removing the stator
- Remove the electric terminal of the minimum oil

pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
Refitting the stator
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.
- Place the cable harness as shown in the figure.
- Stator screws and Pick-Up
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAIL DRAWING.

Stator assembly screws (°) 3 ÷ 4
Refitting the flywheel cover
- Place the flywheel with the top dead centre mark

aligned with the crankcase.
- Place the flywheel cover by aligning the reference
marks of the drive and the crankcase cover.
- Reassemble the cover on the engine, placing the
three connectors in the drive for the water pump.
- Carry out the steps in the reverse order from the
dismantling procedure.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR. MAKE SURE THE CENTRING DOWELS ARE
PRESENT.
ENG - 127

- Place the flywheel with the top dead centre mark aligned with the crankcase.
- Place the flywheel cover by aligning the reference marks of the drive and the crankcase cover.
- Reassemble the cover on the engine, placing the three connectors in the drive for the water pump.
- Carry out the steps in the reverse order from the dismantling procedure.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Flywheel and starting
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Removing the flywheel magneto
- Lock the rotation of the Flywheel with the calliper

spanner tool.
- Remove the nut.
- Take out the flywheel.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
N.B.
THE FLYWHEEL OF THE 200 CM³ MODELS FEATURES
ENHANCED INERTIAL MASS.
ENG - 128

Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key

properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED
Specific tooling
020565Y Flywheel lock calliper spanner

Flywheel nut 54 ÷ 60
Refitting the starter motor
- Fit a new O-ring on the starter motor and lubricate

it.
- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.

Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
ENG - 129

Removing the intake manifold
- Remove the flywheel cover completely as de-

scribed in the flywheel cover section.
- Loosen the 3 crews and remove the intake mani-
fold.
N.B.
TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC
MODELS.
- Remove the flywheel cover completely as described in the flywheel cover section.
- Loosen the 3 crews and remove the intake manifold.
Removing the timing system drive
- Remove the parts listed below first: transmission cover, driving pulley with belt, start-up piston, oil
sump with spring and by-pass piston, oil pump pulley cover, the O-ring on the crankshaft and the pinion
separation washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its
end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft command pulley and its washer.
- Remove the command sprocket wheel and the timing chain.
- Remove the screw indicated in the figure, the spacer and the tensioner slider.
The chain tensioning pad must be removed from the transmission side. As regards the lower chain
guide pad, it may only be removed after the head has been removed.
N.B.
It is advisable to mark the chain in order to guarantee that the initial direction of rotation is maintained.
ENG - 130

ENG - 131

Removing the cam shaft
- Remove the two screws and the cam shaft re-

tainer shown in the diagram.
- Remove the cam shaft.
- Remove the pins and the rocker arms from the
flywheel side holes.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-
OUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
ENG - 132

Removing the cylinder head
- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-
OUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
Removing the valves
- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020306Y Punch for assembling valve seal
rings
ENG - 133

- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
removal tool
rings
Removing the cylinder - piston assy.
- Remove the chain guide pad.

- Pull out the cylinder.
- Remove the cylinder base gasket.
- Remove the two stop rings, the wrist pin and the piston.
- Remove the piston seals.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.
ENG - 134

ENG - 135

Inspecting the small end
- Measure the internal diameter of the small end

using an internal micrometer.
N.B.
REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE
ROD SMALL END EXCEEDS THE STANDARD DIAMETER
OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Characteristic
Rod small end check-up: Maximum diameter
15.030 mm
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
ENG - 136

Inspecting the wrist pin
- Verificare il diametro esterno dello spinotto.

- Calcolare il gioco di accoppiamento piede di biel-
la spinotto.
- Misurare il diametro delle portate sul pistone.
- Calcolare il gioco di accoppiamento spinotto pi-
stone.
- Misurare il diametro esterno del pistone secondo
una direzione ortogonale all'asse dello spinotto.
- Effettuare la misurazione nella posizione mos-
trata in figura.
125 cc: 41,1 mm (dal cielo)200 cc: 5 mm (dalla
base)
- Mediante un alesametro misurare il diametro in-
terno del cilindro secondo le direzioni indicate in
figura e a tre altezze diverse.
- Verificare che il piano di accoppiamento con la
testa non presenti usure o deformazioni.
Massimo fuoripiano ammesso: 0,05 mm
- I pistoni ed i cilindri sono classificati con categorie
in funzione del diametro. L'accoppiamento viene
effettuato alla pari (A-A, B-B, C-C, D-D).
- L'operazione di rettifica del cilindro deve essere
effettuato con una finitura che rispetta l'angola-
zione originale.
- La superficie del cilindro deve presentare una ru-
gosità di 0,9 micron.
- Ciò è indispensabile al fine di garantire un buon
assestamento degli anelli di tenuta, garantendo
così un consumo d'olio ridotto e ottime prestazioni.
Per il motore 125
- Sono previsti pistoni maggiorati per rettifica del
cilindro, suddivisi in tre categorie 1°, 2°, 3° pari a
0,2-0,4-0,6 mm di maggiorazione. Anche questi
sono classificati nelle 4 categorie A-A, B-B, C-C,
D-D.
N.B.
ENG - 137

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.

FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Caratteristiche tecniche
Diametro spinotto: Diametro standard : 200
68,990 ÷ 69,018
Pin diameter Standard diameter: 125 cc
56.997 ÷ 57.025
Diametro spinotto: Pistone : 200
68,933 ÷ 68,961
piston diameter
56.945 ÷ 56.973 mm
Pin diameter: Standard clearance
0.015 ÷ 0.029 mm
Pin diameter Standard diameter
14.996 - 15.000 mm
Wrist pin seat on the piston: Standard diameter
15.001 ÷ 15.006 mm
Diameter of the wrist pin seat on the piston:
Standard clearance
0.001 ÷ 0.010 mm
ENG - 138

Inspecting the piston
- Carefully clean the seal housings.

- Measure the coupling clearance between the
seal rings and the grooves using suitable sensors,
as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
Inspecting the piston rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Measure the opening (see figure) of the sealing rings using a feeler gauge.
- If any measurements are greater than specified, replace the piston rings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN
THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE
CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
ENG - 139

Removing the piston

- Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards
the exhaust.
- Fit the pin stop ring onto the appropriate tool.
- With opening in the position indicated on the tool
S = left
D = right
- Place the wrist pin stop ring into position using a punch
- Fit the wrist pin stop using the plug as shown in the figure
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
Specific tooling
020430Y Pin lock fitting tool
020454Y Tool for fitting piston pin stops (200 - 250)
ENG - 140

Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool
Support to check piston position 020428Y
- Set the dial gauge to zero placing the tool on a contrasting surface. Keeping the zero position, as-
semble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure.
- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)
- Position the dial gauge on the piston as shown in the figure and measure how much the piston pro-
trudes.
- By means of the table shown in the specifications chapter identify the cylinder base gasket thickness
to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct com-
pression ratio.
- Remove the specific tool and the cylinder.
N.B.
PISTON PROTRUSION IS MEASURED IN 125 ENGINES WHILE INTRODUCTION IS MEASURED
IN 200 ENGINES.
ENG - 141

Refitting the piston rings
- Place the oil scraper spring on the piston.

- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The chamfered side of the oil scraper ring should
always be facing the piston crown.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'TOP' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
- The 200 engine takes the 1st segment with L
section.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER BARREL.
Specific tooling
020393Y Piston fitting band
020287Y Clamp to assemble piston on cylinder
ENG - 142

Inspecting the cylinder head
Head check
- Using a trued bar and feeler gauge check that the
cylinder head surface is not worn or distorted.
Maximum allowable run-out: 0.05 mm
- Check that the camshaft and the rocker pin ca-
pacities exhibit no wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Standard diameter
A Ø 12.000 ÷ 12.018 mm
B Ø 20.000 ÷ 20.021 mm
C Ø 37.000 ÷ 37.025 mm
- Using a trued bar and feeler gauge check that the

cylinder head surface is not worn or distorted.
Maximum allowable run-out: 0.05 mm
- Check that the camshaft and the rocker pin ca-
pacities exhibit no wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
ENG - 143

bearing «A»
Ø 12.000 - 12.018 mm
bearing «B»
Ø 20.000 ÷ 20.021 mm
bearing «C»
Ø 37.000 - 37.025 mm
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe

are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you encounter wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn replace
the whole assembly.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
ENG - 144

Inspecting the valve sealings
- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the valve housings
- Check the width of the imprint on the valve

seat«V» wear limit max. 1.6 mm.
- Remove any carbon formation from the valve
guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights
in the rocker arm push direction.
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the speci-
fied limits, replace the cylinder head.
Characteristic
Valve seat wear Intake guide
limit accepted: 5.022
Valve seat wear Intake guide
Standard diameter: 5.000 ÷ 5.012 mm
Valve seat wear Exhaust guide
Accepted limit 5.022
Valve seat wear Exhaust guide
Standard diameter: 5.000 ÷ 5.012 mm
ENG - 145

Inspecting the valves
- Measure the width of the sealing surface on the

valve seats and on the valves.
Sealing surface width: After use: Intake and ex-
haust: 1.6 mm
- If any of the sealing surfaces on the valves is
wider than the specified limit or is damaged in one
or more points, or curved, replace the valve with a
new one.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE
VALVES (RIGHT - LEFT).
Characteristic
Valve wear check Standard: Intake and ex-
haust:
0.99 - 1.27 mm
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
- Check that there are no signs of wear on the sur-
face of contact with the articulated register termi-
nal.
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is ad-
visable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve ax-
es in a horizontal position. This will prevent the
lapping compound residues from penetrating be-
tween the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COM-
POUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
N.B.
DO NOT CHANGE THE POSITIONS THE VALVES ARE FIT-
TED IN
Characteristic
ENG - 146

Valve check standard length

Outlet: 94.4 mm
Inlet: 94.6 mm
Valve check Maximum admissible clearance
Outlet: 0.072 mm
Inlet: 0.062 mm
Valve check standard clearance
Outlet: 0.025 ÷ 0.052 mm
Inlet: 0.013 ÷ 0.040 mm
Valve check Minimum admissible diameter
Outlet: 4.95 mm
Inlet: 4.96 mm
Valve check Standard diameter:
Inlet: 4.972 ÷ 4.987 mm
Outlet: 4.96 ÷ 4.975 mm
ENG - 147

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
- Check that there are no signs of wear on the sur-
face of contact with the articulated register termi-
nal.
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is ad-
visable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve ax-
es in a horizontal position. This will prevent the
lapping compound residues from penetrating be-
tween the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COM-
POUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
N.B.
DO NOT CHANGE THE POSITIONS THE VALVES ARE FIT-
TED IN
Characteristic
Outlet: 94.4 mm
Inlet: 94.6 mm
ENG - 148

Outlet: 0.072 mm
Inlet: 0.062 mm
Outlet: 0.025 ÷ 0.052 mm
Inlet: 0.013 ÷ 0.040 mm
Outlet: 4.95 mm
Inlet: 4.96 mm
Inlet: 4.972 ÷ 4.987 mm
Outlet: 4.96 ÷ 4.975 mm
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.
Refitting the valves
- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seals.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).
Specific tooling
ENG - 149


rings
removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear

on the cams.
- Check the cam height.
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check there are no signs of wear on the auto-
matic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check the rocker pins do not show signs of wear
or scoring.
- Measure the internal diameter of each rocker
arm.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
Characteristic
Internal rocker arm diameter: Standard diame-
ter
Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter
Diameter 11.977 - 11.985 mm
ENG - 150

Cam shaft check: Maximum admissible axial

clearance
0.42 mm
Cam shaft check: Standard axial clearance:
0.11 - 0.41 mm
Cam shaft check: Standard height
Outlet: 29.209 mm
Cam shaft check: Standard height
Inlet: 30.285 mm
Cam shaft check: Minimum admissible diame-
ter
Bearing B diameter: 19.950 mm
Cam shaft check: Minimum admissible diame-
ter
Bearing A Ø: 36.94 mm
Cam shaft check: Standard diameter
Bearing B diameter: 19.959 ÷ 19.98 mm
Cam shaft check: Standard diameter
Bearing A Ø: 36.95 ÷ 36.975 mm
Refitting the head and timing system components
- Refit the lower timing chain sprocket wheel on the

crankshaft, with the chamfer facing the insertion
side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the chain tensioner slider from the cylinder
head side.
- Fit the spacer and the screw fastener.
- Tighten the screws to the prescribed torque.
- Fit the pins and rocker arms.
- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the cam shaft
in the cylinder head with the cams corresponding
to the rockers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed tor-
que.
ENG - 151

- Refit the spacer on the cam shaft.

- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Holding this position insert the chain on the cam-
shaft control pulley.
- Insert the pulley on the cam shaft while keeping
the reference 4V in correspondence with the ref-
erence mark on the head.
- Fit the counterweight and tighten the fixing screw
to the prescribed torque.
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
by approximately 180°.
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed tor-
que.
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the pre-
scribed torque.
- Insert the chain tensioning screw, together with
the spring and washer, tightening it to the prescri-
bed torque.
- Adjust the valve clearance.
- Fit the spark plug.
Electrode distance 0.8 mm
N.B.
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.

Spark plug 12 ÷ 14 Starter ground screw 7 ÷ 8.5
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 11 ÷ 15 Timing
chain tensioner central screw 5 - 6 Camshaft re-
tention plate screw 4 ÷ 6
ENG - 152

- Fit the timing chain guide pad.

- Insert the centring dowel between the cylinder
head to the cylinder, fit the cylinder head gasket
and the cylinder head.
- Lubricate the stud bolt threading.
- Tighten up the nuts to a pre-torque of 7±1 N·m
- Rotate by a 180° angle (2 rotations of 90° each)
- To carry out the operations described above, fol-
low the tightening sequence in the figure.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

ENG - 153

Refitting the intake manifold
Fit the intake manifold and do up the three screws.

N.B.
USE COMMERCIALLY AVAILABLE INSERTS AND INSERT
HOLDERS FOR THE SPECIAL SCREWS FOR 125 CM³
MODELS.
Crankcase - crankshaft
Splitting the crankcase halves

engine crankcase opening
ble>
- First remove the following
units:
transmission cover, driving
pulley, driven pulley and belt,
rear hub cover, gears, bear-
ings and oil seals as descri-
bed in the transmission
chapter.
-Remove the oil sump, the by-
pass, the chain compartment
cover and the oil pump as in
the lubrication chapter.
ENG - 154

- Remove the flywheel cover together with the water pump,
the flywheel and the stator as described in the magneto fly-
wheel chapter.
- Remove the oil filter and the oil pressure switch.
- Remove the cylinder-piston-head unit as described in the
cylinder head timing system chapter.
- Remove the 2 retainers indicated in the figure and the starter
motor.
- Before opening the crank-
shaft, it is advisable to check
the axial clearance of the
crankshaft. To do this, use a
plate and a support with ap-
propriate tool dial gauge.
- Upper clearances are an in-
dication of wear on the surfa-
ces of the crankshaft casing
support.
- Remove the 11 crankcase
coupling screws.
- Separate the crankcase
while keeping the crankshaft
in one of the two halves of the
crankcase.
- Remove the crankshaft.
- Remove the half crankcase
coupling gasket.
- Remove the two screws and
the internal cover shown in
the diagram.
- Remove the oil guard on the
flywheel side.
- Remove the oil filter fitting
shown in the diagram.
- Check the axial clearance
on the connecting rod.
ENG - 155

- Check the radial clearance
on the connecting rod.
-Check the surfaces that limit
the axial free-play are not
scored and measure the
width of the crankshaft be-
tween these surfaces, as
shown in the diagram.
Shim washers (only 200 cc)
- Check the thickness of the
shim washers.
- Check that the shim wash-
ers are not stripped.
- If the axial clearance between the crankshaft and the crank-
case exceeds the established value and the crankshaft does
not present any anomalies, the problem must be due to either
excessive wear or wrong machining on the engine crankcase.
- Check the diameters of both
the bearings of the crankshaft
in accordance with the axes
and surfaces shown in the fig-
ure. The half-shafts are clas-
sified in two categories Cat. 1
and Cat. 2 as shown the chart
below.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
CAUTION
KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES
OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.
N.B.
IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FIT-
TING POSITION.
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
ENG - 156

MODIFIED BY THE RADIUSES OF FITTINGS WITH THE

CRANKSHAFT BEARINGS.
N.B.
The crankshaft of the 200 cm³ version has two steel shim
washers. Take note of their fitting position.
Specific tooling
020262Y Crankcase splitting strip
Characteristic
Crankshaft bearings: Standard diameter: Cat.
2
29.000 ÷ 29.006
Crankshaft bearings: Standard diameter: Cat.
1
28.994 ÷ 29.000
Engine crankcase opening: Standard thick-
ness:
2.175 ÷ 2.225 mm
Width of the crankshaft with shim washers:
standard measurements
51.40 ÷ 51.45 mm
Engine crankcase opening: standard meas-
urements
55.75 ÷ 55.90 mm (125)
Radial connecting rod - crankshaft clearance
Standard clearance
0.036 ÷ 0.054 mm
Axial connecting rod - crankshaft clearance
Standard clearance
0.20 ÷ 0.50 mm
Axial crankshaft/crankcase clearance: Stand-
ard clearance
0.15 - 0.40 mm (when cold)
Inspecting the crankshaft alignment
To install the drive shaft on the support and to

measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
ENG - 157

The connecting rod head bushings cannot be re-

placed. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
CRANKSHAFT ALIGNMENT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft alignment
Measure the capacity of both axes X-Y
STANDARD DIAMETER ( 125 - 200 CM³)

Cat. 1 28.998 ÷ 29.004
Cat. 2 29.004 ÷ 29.010
ENG - 158

Off-line maximum allowed:

A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
Specific tooling
020335Y Magnetic support for dial gauge
020074Y Support base for checking crankshaft alignment
Inspecting the crankcase halves
- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking partic-
ENG - 159

ular care with the cylinder/crankcase surfaces and

the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bearings and con-
nection rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAK CAN CONSIDERABLY DE-
CREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two

- Fit the oil filter fitting and tighten it to the specified
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the locating dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
ENG - 160

For the 200 models reposition the shim washers

as in the original fitting.
- Fit the 11 screws and tighten them to the pre-
scribed torque.
- Lubricate the flywheel oil seal.
- Using the appropriate tool, assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the specified torque.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSE-
QUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 ÷ 6 Oil filter on
crankcase fitting 27 ÷ 33 Engine-crankcase cou-
pling screws 11 ÷ 13 Engine oil drainage plug/
mesh filter 24 ÷ 30
Lubrication
Conceptual diagrams
LUBRICATION CIRCUIT
ENG - 161

ENG - 162

Oil pressure check
- After removing the flywheel cover as described

in the "Flywheel" chapter, remove the electric con-
nexion of the minimum oil pressure switch and
then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the fan cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD
CONDITION.
Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.

ENG - 163

- After removing the flywheel cover as described

in the "Flywheel" chapter, remove the electrical
connexion of the minimum oil pressure switch and
then remove the switch.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the fan cover.
- If the oil pressure is outside the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD
CONDITION.
Specific tooling
020193Y Oil pressure gauge
020434Y Oil pressure control fitting
Characteristic
Oil pressure check: minimum allowed at 6000
rpm
3.2 atm.

ENG - 164

Oil pump
- Check there are no signs of wear on the oil pump

shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the unit.
- Fit the pump cover in the position that permits the
crankcase fixing screws to be aligned.
- Make sure the gasket is positioned properly and
refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the belleville washer.
Tighten to the prescribed torque.
- Fit the oil pump cover by tightening the two
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.

Screws fixing oil pump to crankcase 5 - 6 Oil
pump control crown screw 10 ÷ 14 Oil pump cov-
er screws 0.7 ÷ 0.9
Removal
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley inserting a screwdriver through one of its two holes.
- Remove the central screw with Belleville washer, as shown in the diagram.
- Remove the chain.
- Remove the control sprocket with relative O-ring.
- Remove the oil pump by unscrewing the two screws in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION
OF ROTATION IS MAINTAINED.
ENG - 165

- Use a new oil seal upon refitting.

- Prepare the new oil seal, lubricating the sealing
lip.
- Preassemble the oil seal with the specific tool,
positioning the screws.
- Place the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- Orientate the oil seal by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
- Use the nut to move the base of the tool until you
can feel the end of the oil seal driving stroke.
- Remove all of the tool components following the
inverse procedure
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.
Specific tooling
020622Y Transmission-side oil guard punch
ENG - 166

- Remove the cover of the pump control pulley us-

ing the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
inserting a screwdriver through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain.
- Remove the control sprocket with relative O-ring.
- Remove the oil pump by unscrewing the two
screws in the figure.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
ENG - 167

Inspection
- Remove the two screws and the oil pump cover.

- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
snap ring.
- Check the clearance between the rotors in the
position shown in the diagram using a thickness
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
ENG - 168

Removing the oil sump
- Remove the oil filler plug, the transmission cover,

the complete driving pulley assembly with belt and
the sprocket wheel, as described in the "Trans-
mission" chapter.
- Drain the oil as described previously.
- Remove the seven screws, shown in the dia-
gram, and the two rear brake fluid pipe fixing
brackets.
- Remove the screw, the by-pass piston, the gas-
ket and centring dowels shown in the figure.
Inspecting the by-pass valve
- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 169

Refitting the oil sump
- Refit the by-pass valve plunger in its housing.

- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the two centring dowels.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake cable brackets and the
screws in the reverse order from which they were
removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as de-
scribed in the "Transmissions" chapter.
- When testing the lubrication system, refer to
chapter "Crankcase and Crankshaft", regard-
ing lubrication of the crankshaft and connect-
ing rod

Oil sump screws 10 ÷ 14
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.

- Provisionally assemble the rubber coupling of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rub-
ber coupling as shown in the photograph.
- Set the pump to the low-pressure position (VAC-
UUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
ENG - 170

- Switch the pump to pressure mode (PRES-

SURE).
- Operate the pump slowly and check if there is an
increase of pressure. A small leakage is consid-
ered to be normal.
If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN
RUBBER COUPLING AND FILTER OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEAL-
ING
Specific tooling
Inspecting the cut-off
- Remove the SAS valve.

- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber coupling
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum re-
acts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
There follows a slow and continuous loss of de-
pression up to approximately 0.4 BAR. At this point
ENG - 171

the valve opens and the depression is suddenly

set to zero.
Lack of tightness or the fact that the valve opens
at different vacuum values should be regarded as
anomalies. In this case, replace it.
N.B.
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS
IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER). IN-
CORRECT CUT-OFF VALVE CALIBRATION CAN RESULT
IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES
JEOPARDISING THE CORRECT OPERATION OF THE
CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
Fuel supply
- To clean the filtering element proceed as follows:

remove the 4 filter cover fixing screws indicated in
the figure; remove the cover and take out the pa-
per filtering element, clean with compressed air
and refit.
- Make sure the filtering element is in the correct
position.
- Check that the air passage sections are not dam-
aged or deformed.
- Check the correct sealing of the coupling be-
tween the filter housing and the cover.
N.B.
FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RE-
SULT IN WRONG VACUUM INSIDE THE FILTER HOUSING,
WHICH IN TURN MAY PRODUCE VARIATIONS IN CARBU-
RETION.
ENG - 172

Removing the carburettor

carburettor removal
ble>
- To detach the carburettor
from the engine, move the air
filter and remove the throttle
control transmission, the au-
tomatic starter connection,
the clamps anchoring the car-
burettor to the filter housing
and to the inlet manifold, the
air delivery pipe to the dia-
phragm, and the intake fitting.
- Take out the carburettor and
rotate it so as to remove the
screw with the water joint and
the pipes.
- Remove the protection, the
bracket and the starter oper-
ating on the 2 screws shown
in the figure.
- Remove the 2 screws and
the starter support with the
gasket.
- Remove the fixing screw
shown in the figure, the rock-
ing lever and the accelerating
pump control spring.
- Remove the 2 fixing screws
indicated in the figure, the
vacuum chamber cover and
the spring.
- Remove the vacuum valve
together with the diaphragm.
- Remove the 4 screws
shown in the figure and the
chamber with the gasket.
ENG - 173

- Remove the accelerating
pump piston with the ring nut,
the hood, the O-Ring and the
spring from the chamber as
- Adequately support the car-
burettor and using a pin and
hammer; remove the float pin
operating from the throttle
control side.
- Remove the float and the
plunger.
- Remove the cover of the air
deflector from the carburettor
to the starter nozzle as shown
in the figure.
-Remove the maximum noz-
zle.
-Remove diffuser.
- Remove the sprayer.
-Remove the minimum noz-
zle.
- Remove the minimum flow
screw with the O-ring, the
washer and the spring.
- For the 200 cm³ version on-
ly, remove the two fixing
screws, the cover, the spring
and the diaphragm of the cut-
off device.
N.B.
This last operation is necessary so as no to empty the cooling
system. For the 200 cm³ version only, disconnect the low-pres-
sure supply pipe to the cut-off device.
WARNING
- While removing the cover, pay attention not to release the
spring accidentally.
N.B.
This operation is necessary to avoid losing sprayer parts when
cleaning the carburettor body. If the sprayer is forced in its
housing, do not attempt to remove it as this will only damage
it.
ENG - 174

CAUTION
- Do not attempt to remove parts embedded in the carburettor
body, such as: fuel supply pipe, plunger housing, starter nozzle,
pit cover for progressions and inlet nozzle, minimum and max-
imum air gauge, throttle valve control shaft. Do not remove
throttle-shaft connecting screws. The fixing screws are caulked
after fitting and removing them damages the shaft.
ENG - 175

Kehin
- To detach the carburettor from the engine, it is

necessary to move the air filter and remove the
transmission throttle control, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, and the intake
fitting.
- Take out the carburettor and rotate it so as to
remove the screw with the water joint and the
pipes.
N.B.
THIS LAST OPERATION IS NECESSARY SO AS NO TO
EMPTY THE COOLING SYSTEM.
- Remove the protection, the bracket and the start-

er acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with

the gasket.
ENG - 176

- Remove the clamp and cover with the airing filter

of the diaphragm chamber.
- Remove the 4 fixing screws shown in the figure

and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER
TAKE SPECIAL CARE NOT TO RELEASE THE SPRING
ACCIDENTALLY.
- Remove the vacuum valve together with the di-

aphragm.
ENG - 177

- Unscrew the bayonet joint 1/8 of a turn and re-

move, take out the spring and vacuum valve nee-
dle
- Remove the 4 screws indicated in the figure.
- Remove the chamber with the accelerating

pump, its control and gasket.

- Remove the intake and outlet valves of the intake
pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP VALVES ARE
MADE UP OF NOZZLES, SPRING AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
ENG - 178

Adequately support the carburettor and using a

rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
-Remove the maximum nozzle.
ENG - 179

-Remove diffuser.
- Remove the sprayer.

N.B.
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY-
ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
ENG - 180

- Remove the minimum flow set screw and the

spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNEC-
TION SCREWS. THE FIXING SCREWS ARE CAULKED AF-
TER ASSEMBLY AND THEIR REMOVAL DAMAGES THE
SHAFT.
Refitting the carburettor
Kehin
- The screw final position should be determined by

an exhaust fume analysis.
- Adjust the carburettor by turning the screw twice
from the close position.
ENG - 181

ENG - 182

ENG - 183

Level check
Kehin
- Place the carburettor inclined as shown in the

figure.
- Check that the float reference is parallel to the
tank coupling surface
- If different positions are detected, change the
plunger control metal plate direction to obtain the
position described above.
Kehin
- Check that the tapered pin of the vacuum valve

does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
ENG - 184

- Reassemble the vacuum valve on the carburettor

body taking care that the tapered pin is inserted
into the sprayer.
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being
careful to correctly insert the spring in its place on
the cover.
- Tighten the screws to the prescribed torque
- Wash and blow dry the filter sponge of the am-
bient pressure intake.
- Reassemble the filter with its clamp.
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE
POSITION.

Vacuum chamber cover screws: XX Nm
ENG - 185

Inspecting the automatic choke device
- Check that the piston of the automatic starter is

not deformed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the sealing gasket of the piston is not
deformed.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check the corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that piston protrudes as much as possible.
- The correct warm up time depends on the ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
ENG - 186

plate with the machined side contacting the starter,

tighten the 2 fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
Characteristic
Check the auto starter: Protrusion Value for
Walbro
12.5 ÷ 13 mm at approx. 20°C
Check the automatic starter: maximum protru-
sion
18.5 ÷ 19 mm
Check the automatic starter: Max. time:
5 min
Check the automatic starter: Resistance
around 30 Ω
Kehin
- Check that the automatic starter piston is not de-

formed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not de-
formed.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possi-
ble.
ENG - 187

- The correct warm up time depends on the ambi-

ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION
NOT TO GENERATE SHORT CIRCUITS USE A CABLE
SECTION WITH A TERMINAL SUITABLE TO BE CONNEC-
TED TO THE STARTER.
Characteristic
Check the automatic starter: Kehin: Protrusion
value
XX ÷ XX mm at approx. 20°C
Check the automatic starter: Kehin maximum
protrusion
XXX ÷ XXX mm
Check the automatic starter: Keihin maximum
time
5 min
Adjusting the idle
- The engine does not need frequent idle adjust-

ments, however it is very important to make any
adjustments fully respecting some standards.
- Before adjusting the carburettor make sure to re-
spect the lubrication requirements, valve clear-
ance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 mi-
nutes at approximately 50 kph.
ENG - 188

- Connect the vehicle to the exhaust fumes analy-

ser inserting the probe into a sealed extension pipe
placed at the muffler exit end.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly pre-
pared for probes.
- Start the motor and before adjusting the idle
speed make sure that the oil temperature is be-
tween 70 ÷ 80°C.
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm ÷ 1700 rpm
- Adjust the flow screw until the carbon monoxide
(CO) percentage is 3.1 ÷ 4.5%, when the screw is
loosened the CO value rises (rich mix). Tightening
the screw decreases the CO (lean mix).
- If the adjustment of the flow screw causes a rpm
increase readjust the revs again and if necessary,
the flow screw to reach stable values.
- When the oil temperature, the numbers of revs
and the percentage of carbon monoxide are re-
spected the idle carburetion is considered correct.
From the analyser we can draw further informa-
tion:
- carbon dioxide percentages (CO2), the percent-
age of carbon dioxide has an inverted course com-
pared to the percentage of(CO), values over
12.5% are considered correct. Non complying val-
ues indicate lack of tightness in the exhaust sys-
tem.
- Unburned hydrocarbons (HC) are measured in
parts per million (PPM). The HC value decreases
while the rpm increases; with the engine at idle it
is normal to detect 200 ÷ 400 PPM, these emission
values are deemed normal for an engine with a
diagram of distribution for motorcycles. Higher val-
ues can cause loss of engine blows as the mixture
ENG - 189

is too lean (low CO), ignition failure or, incorrect

timing or a clogged or unsealed exhaust valve.
- If it were difficult to ???? adjustment CO check
accurately:
- That the carburettor is clean
- That the automatic starter is efficient
- Tapered pin housing efficiency
- Tank level adjustments
N.B.
THE EXTENSION TUBE IS INDISPENSABLE SO AS NOT
TO SEND POLLUTED EXHAUST FUMES TO THE AMBIENT
OXYGEN. IT IS INDISPENSABLE TO USE AN EXHAUST
FUMES ANALYSER PREVIOUSLY HEATED AND PRE-
PARED TO GUARANTEE THE RESET OF THE READING
OF GASES AND THE CORRECT GAS CAPACITY. FAILURE
TO RESPECT THESE REGULATIONS RESULTS IN INAC-
CURATE READINGS.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000
Characteristic
Idle adjustment: Pipe sizes
Ø 40 mm
Idle adjustment: length
500 ÷- 600 mm
ENG - 190

INDEX OF TOPICS
SUSPENSIONS SUSP

Suspensions Carnaby 125 - 200
Front
Removing the front wheel
- Remove the front calliper.
- Loosen the wheel axle lock-nut.
- Loosen the two wheel axle safety screws on the fork leg, on the brake calliper side.
- Pull out the wheel axle.
Front wheel hub overhaul
Check that the wheel bearings do not show signs

of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the plastic cover on the tone wheel side
to avoid damage by loosening the 5 fixing screws.
- Remove the two bearings on the odometer drive
side using the pliers 14 or 34 and the bell detail 9.
- Remove the internal spacer.
SUSP - 192

Carnaby 125 - 200 Suspensions
* Either tool can be used.
- Support the front wheel with two wooden shims

that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch (consisting of adaptor handle,
15 mm adaptor and guide) from the odometer drive
side to permit the removal of the brake disc side
bearing and the spacer bushing.
Specific tooling
020412Y 15 mm guide
- Heat the bearing seat on the side the brake disc
with the heat gun.
- Insert the bearing using the punch consisting of

adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.
SUSP - 193

- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.
Specific tooling
020412Y 15 mm guide
020201Y Spacer bushing driving tube
- Turn over the wheel and insert the internal spacer
with the part fitted with the Seeger ring facing the
bearing on the brake disc side installed previously.
- Heat the bearing seat on the odometer drive side

with the heat gun.
- Insert the two bearings using the punch consist-

ing of adaptor handle, 32x35 mm adaptor and 15
mm guide, and drive it up to the stop.
Specific tooling
020412Y 15 mm guide
SUSP - 194

- Refit the cap and tighten the five fixing screws.
Refitting the front wheel
- Grease the wheel axle, then install it from the

tone wheel side and install the tone wheel proper-
ly.
- Tighten the wheel axle nut to the prescribed tor-
que.
N.B.
TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE.
FOR THE SAKE OF SAFETY, OFFSET THE INTERNAL
STOP FROM THE STOP OF THE TONE WHEEL BY 90°.
- Tighten the two safety screw on the leg to the

prescribed torque.

Front wheel axle nut 45 - 50 Safety screw on fork
leg 6 ÷ 7
Handlebar
SUSP - 195

Removal
- Remove the front handlebar cover.

- Remove the rear handlebar cover.
- Remove the fixing pin.
- Remove the handlebar resting it on the shield
back plate.
If you want to remove the fork, proceed as follows:

- Remove the rear handlebar cover by disconnect-
ing the odometer cable and the instrument panel
connectors.
- Remove the brake pumps.
- Release the throttle control.
- Remove the fixing pin.
- Remove the handlebar.
Refitting
- Install the handlebars on the steering tube, pay-

ing attention to the centring, aligning the recess on
the handlebar with that on the steering tube as
- Tighten the handlebar fixing screw on the steer-
ing tube to the prescribed torque.

Handlebar fixing screw (*) 45 ÷ 50
(*) Lubricate the nuts with engine oil before installation
Front fork
SUSP - 196

Removal
- Remove the front wheel.

- Remove the handlebar.
- Using the appropriate tool, loosen and remove
the upper ring nut, the distancing washer, the
counter ring nut and the spacer ring.
- Extract the fork.
N.B.
TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT
IT FROM COMING OFF ABRUPTLY
Specific tooling
See also
Removal
Overhaul
- With the 10 mm hexagonal wrench for internal

parts loosen the upper stem closing cap.
- Loosen the stem support clamp and remove fork

leg and stem.
SUSP - 197

- Remove the first spring featuring 15 turns.

- Remove the spring support plate.
- Remove the second spring featuring 21 turns.
- Drain the oil.
- Separate the stem from the leg by removing the
screws with copper washer shown in the figure. To
prevent the rotation of the pumping insert a 12 mm
hexagonal wrench for internal parts in the stem.
- Remove the dust guard ring using a screwdriver

- Remove the oil guard safety lock using a screw-

driver.
- Using the appropriate special tool, remove the oil
seal.
- Insert the tie rod complete with cable into the oil
guard.
- Insert in sequence the two half-rings per Ø 35-
mm stems.
- Keeping the tie rod in vertical position, insert the

bell for the Ø 35 mm stems.
- Insert the nut in the thread and take out the oil
guard
Specific tooling
020487Y Fork oil seal extractor
SPRING LENGTH CHECK

Standard length 15-turn spring: 116.3 + 2-1 mm
Allowable limit after use: 15-turn spring: 114.3 mm
SUSP - 198

Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the
damaged parts.
Characteristic
Maximum leg diameter
35.10 mm
Minimum stem diameter
34.90 mm
Check that the oil holes on the pumping element

are not clogged. - Check that the O-ring shows no
sign of damage.
- Insert a new oil guard with the special adaptor

handle and take it to the stop.
- Insert the safety clip.
- Insert a new dust guard.
SUSP - 199

- Insert the contrast spring into the pumping mem-

ber.
- Insert the pumping element inside the stem.
- Insert the pumping element guide bushing at the
lower stem end.
- Insert the stem in the leg being careful not to let
the stem guide bushing come out.
- Inset and screw up the copper washer to the pre-

scribed torque. To prevent the pumping member
from rotating, insert a 12 mm Allen key into the
stem.
- Pour 102 ± 1 cm³ of oil into the stem.
AGIP FORK 7.5 W Fork oil
Grade 7.5 W
- Insert the 21 winding springs, the support plate

with the chamfer facing downwards and then the
15 winding spring.
- Insert the stem into the fork clamp.

- Do up the clamp once to allow the stem closure
upper cap to be tightened.
- Check that the sealing ring on the cap is in good
working order, then tighten the cap on the stem to
the prescribed torque.
SUSP - 200

- Loosen the fork clamp screws and ensure the

stem closure cap is fitted properly on the clamp.
- Tighten the clamp screws to the prescribed tor-
que.
Specific tooling

Fork clamp screws 20 ÷ 25 Stem upper cap 15 ÷
30 Lower screw with copper washer 25 - 35
- Check that the roller bearing does not show signs

of wear or pricking.
In case of replacement, proceed as follows:
- Support the fork in a vice.
- Insert the contrast plate in the upper end of the
steering tube
N.B.
ONLY REMOVE THE UPPER BALL BEARING IF YOU
REALLY NEED TO.
- Insert the special tool as shown in the figure.
- Insert the retaining band of the two half-rings.
SUSP - 201

- Using a 19 mm hexagonal spanner, extract the

roller bearing.
Specific tooling
020458Y Puller for lower bearing on steering
tube
- Insert the a new plate and a new dust guard in

the steering tube
- Insert a new roller bearing in the roller tube.
- Using the special tool and a mallet to move the
dust guard and the bearing in abutment.
Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube
- With the 10 mm hexagonal wrench for internal

parts loosen the upper stem closing cap.
- Loosen the stem support clamp and remove fork

leg and stem.
SUSP - 202

- Remove the first spring featuring 15 turns.

- Remove the spring support plate.
- Remove the second spring featuring 21 turns.
- Drain the oil.
- Separate the stem from the leg by removing the
screws with copper washer shown in the figure. To
prevent the rotation of the pumping insert a 12 mm
hexagonal wrench for internal parts in the stem.
- Remove the dust guard ring using a screwdriver

- Remove the oil guard safety lock using a screw-

driver.
- Using the appropriate special tool, remove the oil
seal.
- Insert the tie rod complete with cable into the oil
guard.
- Insert in sequence the two half-rings per Ø 35-
mm stems.
- Keeping the tie rod in vertical position, insert the

bell for the Ø 35 mm stems.
- Insert the nut in the thread and take out the oil
guard
Specific tooling
020487Y Fork oil seal extractor
- Check the length of the springs.
SPRING LENGTH CHECK

SUSP - 203

Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the
damaged parts.
Characteristic
Maximum leg diameter
35.10 mm
Minimum stem diameter
34.90 mm
Check that the oil holes on the pumping element

are not clogged. - Check that the O-ring shows no
sign of damage.
- Insert a new oil guard with the special adaptor

handle and take it to the stop.
- Insert the safety clip.
- Insert a new dust guard.
SUSP - 204

- Insert the contrast spring into the pumping mem-

ber.
- Insert the pumping element inside the stem.
- Insert the pumping element guide bushing at the
lower stem end.
- Insert the stem in the leg being careful not to let
the stem guide bushing come out.
- Inset and screw up the copper washer to the pre-

scribed torque. To prevent the pumping member
from rotating, insert a 12 mm Allen key into the
stem.
- Pour 102 ± 1 cm³ of oil into the stem.
AGIP FORK 7.5 W Fork oil
Grade 7.5 W
- Insert the 21 winding springs, the support plate

with the chamfer facing downwards and then the
15 winding spring.
- Insert the stem into the fork clamp.

- Do up the clamp once to allow the stem closure
upper cap to be tightened.
- Check that the sealing ring on the cap is in good
working order, then tighten the cap on the stem to
the prescribed torque.
SUSP - 205

- Loosen the fork clamp screws and ensure the

stem closure cap is fitted properly on the clamp.
- Tighten the clamp screws to the prescribed tor-
que.
Specific tooling

Fork clamp screws 20 ÷ 25 Stem upper cap 15 ÷
30 Lower screw with copper washer 25 - 35
Refitting
- Grease using lithium soap grease on the roller

bearings.
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
- Insert the fork into the headstock.

- Insert the spacer ring.
- Using an appropriate tool do up the first ring nut
in the steering tube (upper steering ball bearing).
Tighten to the prescribed torque.
- Install the space washer.
- Using the special tool, tighten the second locking
ring nut in the steering tube to the prescribed tor-
que.
Specific tooling

Steering lower ring nut 10 ÷ 13 then loosen by 90°
Upper steering ring nut 30 ÷ 36
Steering bearing
SUSP - 206

Removal
- Remove the fork

- Check that the upper ball bearing and the seat of
the lower roller bearings do not show signs of wear
or pricking.
In case of replacement, proceed as follows:
- Using a punch to remove the bearings, insert it
from the bottom and remove the ball bearing
above the headstock. Then remove the lower seat
of the roller bearing by inserting the punch from the
top of the headstock.
N.B.
ONLY REMOVE THE UPPER BALL BEARING IF YOU
REALLY NEED TO.
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
See also
Removal
Refitting
Using the appropriate tool, refit the upper ball bear-

ing and the seat of the lower roller bearings on the
headstock as described below:
- Place a new ball bearing on the headstock and a
roller bearing seat on the lower part.
- Insert the tie rod screw of the appropriate tool
fitted out with the adaptors for planting the bearing
and seat it in the headstock as in the photograph.
- Using two 24 mm wrenches, tighten the screw
until the seat and the bearing are fully set in place.
N.B.
ALWAYS USE A NEW BEARING AND A NEW SEAT.
Specific tooling
001330Y Tool for fitting steering seats
Rear
SUSP - 207

Removing the rear wheel
- Remove the exhaust silencer.

- Unscrew the shock absorber lower clamp and
rotate the shock absorber towards the scooter rear
part.
- Remove the cotter pin and the cap.
- Loosen the nut and collect the spacer.
- Remove the two screws fixing the right shock ab-

sorber support bracket and remove the bracket.
SUSP - 208

- Remove the five screws fixing the wheel to the

hub.
- Remove the wheel and collect the conical spacer.
Refitting the rear wheel
- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.

Fixing screw for wheel rim to hub 34 ÷ 38
Swing-arm
Removal
WARNING
IT IS NOT NECESSARY TO REMOVE THE SWINGING ARM TO SERVICE IT.
- Rest the scooter on its centre stand.
- Remove the side spoilers.
- Remove the footrest.
- Support the engine adequately.
- Unscrew the pin connecting the swinging arm to
the engine and collect the spacer.
- Operating from both sides of the scooter, loosen

the nut from the inside and collect the washer.
SUSP - 209

- Remove the pin from the silent bloc.
- Once the swinging arm on the engine side is re-

leased, release the swinging arm on the frame
side, operating on both sides.
- Loosen the nut and collect the washer.
- Remove the pin connecting the swinging arm to

the frame.
- Remove the swinging arm by pulling it forwards.
Overhaul
WARNING
THE SWINGING ARM CLEARANCE MUST BE CHECKED WITH THE ARM MOUNTED IN RIDING
CONDITIONS.
SUSP - 210

- Remove the side spoilers.

- Check the axial clearance between the two
swinging arms using a thickness gauge.
- If non-conforming values are detected, remove
the swinging arm and replace the Teflon spacer
bushings.
Characteristic
Axial clearance between the two swinging
arms
Min 0.6 Max 1.2 mm
- Check clearances between the arm on the frame

side and the frame using a thickness gauge.
- If non-conforming values are detected, remove
the swinging arm and replace the Teflon spacer
bushings.
Characteristic
Clearance between the bushing and the plates
Min 0.6 Max 1.2 mm
- To check the silent bloc, loosen the nut from the

inside, undo the screw and remove the silent bloc.
- Make sure it is not broken. If it does, replace it.
- To remove the roller casings, take out the Teflon spacer bushing and the internal spacer «A».
- Using an appropriate pin, remove the roller casings «B».
- Using an appropriate tool, set new roller casings, being careful to place the bearings with the O-rings
facing outwards.
- Once fitted, lubricate the ball cages with the recommended product.
Specific tooling
020115Y Ø 18 punch
020244Y 15 mm diameter punch
AGIP GREASE PV2 Grease for control levers on the engine
White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C
and +120 °C; NLGI 2; ISO-L-XBCIB2
SUSP - 211

Refitting

- Tighten to the prescribed torques.
SWINGING ARM FITTING

Name Torque in Nm
Swinging arm on engine side - Engine 40
Silent bloc - Frame 54
Swinging arm on frame side - Frame 60
Swinging arm on engine side - Swinging arm on frame side 61
Shock absorbers
Removal
Proceed as follows:
- Place the scooter on its centre stand;
- Lift the engine using a jack so as to free both
shock absorbers.
- Remove the muffler.
- Undo the screws fixing the shock absorber spring
unit from the support fixed to the engine on one
side.
SUSP - 212

- Loosen the nut fixed to the muffler support on the

other side.
- Undo the two upper nuts (one on each side) fixing

the shock absorber spring unit to the frame and
remove the shock absorbers themselves.
Refitting
Carry out the previous operations but in reverse order.

Lower shock absorber clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41
Exhaust bracket
Removal
- Remove the muffler.

- Loosen and remove the lower retaining bolt of the
right-hand shock absorber at the support arm.
- Undo the two screws fixing the arm to the engine.
SUSP - 213

- Remove the split pin and safety cover;
- Unscrew the wheel axle nut; to prevent the wheel

from rotating, use the rear brake and collect the
spacer.
- Remove the support arm.
See also
Exhaust assy. Removal
Overhaul
- Remove the circlip shown in the photograph
- Support the muffler support bracket sufficiently

- Using the special punch, remove the bearing
from its seat as shown in the photograph
Specific tooling
SUSP - 214

- Heat the bearing seat using the heat gun

- Using the special punch, install a new bearing in
the seat as shown in the photograph
Specific tooling
020151Y Air heater
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

Rear wheel axle nut 104 ÷ 126 Muffler support arm to engine screws (*) 20 ÷ 25 Lower shock
absorber clamp 33 ÷ 41
Centre-stand
- Remove the muffler

- Remove the two stand return springs.
- Detach the rear brake pipe from the clamps, un-

screw the fixing nut and collect the washer.
- Slide off the pin and remove the stand.

- To refit, carry out these operations in reverse order.
- Tighten the nut to the prescribed tightening torque.
CAUTION
LUBRICATE THE FOLLOWING PARTS WITH GREASE: SPRING COUPLING PINS, BUSHINGS ON
STAND FIXING BRACKETS.
SUSP - 215

AGIP GREASE PV2 Grease for control levers on the engine
White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C
and +120 °C; NLGI 2; ISO-L-XBCIB2

Bolt fixing the centre stand to the frame 25 ÷ 30
SUSP - 216

INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system Carnaby 125 - 200
Interventions rules
WARNING
BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE
EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELL
WITH ABUNDANT WATER.
THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COL-
LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS
IN FORCE. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THE FLUID EVERY TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CON-
DITIONS, CHANGE THE FLUID MORE FREQUENTLY.
DURING INSTALLATION, THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN AND
FREE FROM ANY TRACES OF OIL, FUEL AND GREASE: IT IS THEREFORE NECESSARY TO
CLEAN THEM THOROUGH WITH DENATURED ALCOHOL.
N.B.
FOR TOPPING UP AND CHANGE, USE ONLY BRAKE FLUID DOT4 - NHTSA 116.
OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS. HYDRAULIC FLUID IS EXTREMELY
CORROSIVE FOR PAINTED SURFACES.
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR.
IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RE-
SULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID.
N.B.
ALWAYS USE FLUID FROM SEALED CONTAINERS.
N.B.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL LONGER THAN 20 SECONDS. AFTER
WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN
CLOTH.
THE SEAL RINGS MUST BE IMMERSED IN THE OPERATING FLUID; THE USE OF PRF1 PRO-
TECTIVE DEVICE IS ALLOWED.
WARNING
THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFI-
CIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY
SOLVENT.
Rear brake calliper
Removal
- Make sure the brake pipes and the joint are in

good conditions. Remove and repair the calliper in
the event of fluid leaks.
- Disconnect the brake fluid pipe from the calliper,
pouring the fluid inside a container.
BRAK SYS - 218

Carnaby 125 - 200 Braking system
- Undo the screws fixing the calliper support to the

engine.
Refitting
- Fix the brake calliper support plate to the crank-

case and the brake calliper to the bracket, tight-
ening the screws to the prescribed torque.
- Apply the recommended product to the fixing
screws of the brake calliper to the bracket.
- Purge the system.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON
THEIR FITTINGS.
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock

Oil bleed screw 12 - 16 Screw tightening calliper
to the support 23 ÷ 25 Screw fixing rear brake
calliper support to engine 20 ÷ 25 Brake fluid
pipe-calliper fitting 16 ÷ 20
See also
Rear - combined
Front brake calliper
BRAK SYS - 219

Removal
- Make sure the brake pipes and the joint are in

good conditions. Remove and repair the calliper in
the event of fluid leaks.
- Disconnect the brake fluid pipe from the calliper,
pouring the fluid inside a container.
- Undo the screws fixing the brake calliper support

to the fork.
Overhaul
Proceed as follows:
1) remove the two male hexagonal screws (1) and
take out the two pads (10);
2) remove the two male hexagonal screws (2) and
remove the reaction plate (3);
3) take out the fixed plate (4) from the guide;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the cal-
liper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
BRAK SYS - 220

- that the guides of the fixed plate are not scratched

or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Refitting
1) insert the pistons (6) and the sealing rings (7) in
the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corre-
sponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction prin-
ciple to obtain the thrust for both pads.
The body and the reaction plate body work inte-
grally and can move axially with respect of the
fixed plate that is integral to the strut.
The pistons, forced by pressure to push the pad to
the disk, cause the reaction plate to push in turn
the other pad towards the disc.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
BRAK SYS - 221

ALL THE SEALS AND GASKETS MUST BE REPLACED EV-

ERY TIME THE CALLIPER IS SERVICED.

Brake fluid pipe-calliper fitting 20 ÷ 25 Pad fas-
tening pin 19.6 ÷ 24.5
Refitting
- When refitting, tighten the nuts to the prescribed

torque.
- Reconnect the brake pipe.
- Purge the system.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON
THEIR FITTINGS.

Oil bleed screw 12 - 16 Screw tightening calliper
to the support 20 ÷ 25 Brake fluid pipe-calliper
fitting 16 ÷ 20
Rear brake disc
Removal

- Remove the brake calliper.
- Remove the hub and the brake disc.
- Carry out the same procedure with the front brake

disc.
See also
BRAK SYS - 222

Removing the rear wheel
Refitting
- For the installation, position the disc correctly using the arrow stamped on it as reference.
- Tighten the screws to the prescribed torque and apply the recommended product.
N.B.
THE SURFACE OF THE DISC WITH THE STAMPED ARROW FOR THE DIRECTION OF ROTATION
MUST FACE TOWARDS THE OUTSIDE OF THE SCOOTER.

Brake disc fixing screws 11 ÷ 13
Disc Inspection
Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.
Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (rear)
3.5 mm
- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake disc
BRAK SYS - 223

Removal
Proceed as follows:
- Remove the front wheel.
- Loosen the five disc fixing screws.
- Thoroughly clean the seats on the front wheel
hub and on the disc.
See also
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.

Brake disc fixing screw 5 ÷ 6.5
Disc Inspection
Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.
Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm
BRAK SYS - 224

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake pads
Removal
Proceed as follows:
- Remove the front calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
See also
Front
brake calliper
Refitting
To fit, proceed as follows:

- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
BRAK SYS - 225


Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5
Rear brake pads
Removal
Proceed as follows:
- Remove the rear brake calliper
- Remove the two pins holding the brake pads.
- Remove the pads, paying attention to the pad re-
taining spring.
- Check the thickness of the pads.
If the thickness is less than the minimum value,
replace the pads with new pads.
Characteristic
Minimum value
1.5 mm
See also
Removal
Refitting
Carry out the installation by analogy with the procedure described for the installation of the rear brake
calliper.
- Tighten the two calliper fixing screws to the prescribed tightening torque.

Pad fastening pin 19.6 ÷ 24.5 Screw tightening calliper to the support 20 ÷ 25 Fixing screws for
the calliper support on the engine 20 ÷ 25
Fill
BRAK SYS - 226

Rear - combined
Proceed as follows:
- Position the vehicle on a flat surface and on the
stand
- Loosen the two screws shown in the figure and
open the front brake fluid reservoir.
- Through the bleed screw on the brake calliper,

bleed the system using a hose of adequate diam-
eter.
- Collect the used fluid in a container.
- Pump on the brake lever to completely drain the system of all used fluid.
- Tighten the bleed valve.
- Refill the brake system tank up to the maximum level with the prescribed fluid.
- Attach the tube of the special tool to the bleed fitting.
- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to
prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is
finished when only brake fluid comes out of the bleed screw.
- Close the bleed screw and tighten to the prescribed torque.
- Close the brake system tank.
N.B.
IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-
TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUT
THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND
ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE
DISC.
Specific tooling

BRAK SYS - 227

Front
Proceed as follows:
- Position the vehicle on a flat surface and on the
stand
- Loosen the two screws shown in the figure and
open the front brake fluid reservoir.
- Through the bleed screw on the brake calliper,

bleed the system using a hose of adequate diam-
eter.
- Collect the used fluid in a container.
- Pump on the brake lever to completely drain the system of all used fluid.
- Tighten the bleed valve.
- Refill the brake system tank up to the maximum level with the prescribed fluid.
- Attach the tube of the special tool to the bleed fitting.
- Actuate the tool at the bleed fitting, at the same time constantly topping up the brake system tank to
prevent air being drawn into the system, until no more air escapes at the bleed fitting. The operation is
finished when only brake fluid comes out of the bleed screw.
- Close the bleed screw and tighten to the prescribed torque.
- Close the brake system tank.
N.B.
IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FIT-
TINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUT
THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND
ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE
DISC.
Specific tooling

BRAK SYS - 228

Front brake pump
Removal
- Drain the braking system.
- Disconnect the brake fluid pipe from the pump,
paying attention to a possible escape of remaining
brake fluid.
- Remove the front brake stop button from the lev-
er.
- Loosen the two fixing screws of the stand and

remove together with the rear view mirror.
- Remove the front brake pump together with the
lever.
See also
Rear handlebar cover
Front
Overhaul
1) Remove the brake lever by loosening the fixing screw;
open the cover (2) and take out the diaphragm (3);
2) Remove the cap and unscrew the internal parts in the specified order;
3) Check that:
- The body of the pump shows no signs of internal damage or corrosion;
- The piston shows no sign of damage or abnormal wear;
- The piston return spring is in good condition.
Refitting
Reinstall the individual parts in the reverse order to the removal, paying attention to the correct posi-
tioning of the rubber parts in order to ensure leak tightness.
1. Tank cover screw
2. Tank cover
3. Diaphragm
4. Bellows
BRAK SYS - 229

5. Seal ring
6. Piston
7. Gasket
8. Spring
9. Tank
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
Refitting
- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Front
Rear brake pump - combined
Removal

- Drain the braking system.
- Disconnect the brake oil pipe from the pump,
paying attention to a possible escape of remaining
oil.
- Remove the rear brake stop button from the lev-
er.
BRAK SYS - 230

- Loosen the two fixing screws of the stand and

remove together with the rear view mirror.
- Remove the front brake pump together with the
lever.
See also
Rear - combined
Refitting
- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Front
BRAK SYS - 231

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

Carnaby 125 - 200 Cooling system
Circuit diagram
COOLING CIRCUIT
A Fluid cooling circuit
B Thermostat with By-Pass
COOL SYS - 233

Cooling system Carnaby 125 - 200
C Expansion tank
D Radiator
E Carburettor heating circuit
Electric fan check
KEY:
5. Fuse unit
11. Battery
31. Thermoswitch
32. Electric fan
Electric fan operation check

To carry out the electric fan operation check, pro-
ceed as follows:
- Remove the front shield.
- Disconnect the two electric terminals from the
thermoswitch and connect them together.
COOL SYS - 234

If it does not work:

- Make sure the connector is properly inserted.
- Rotate the fan manually and check that the blades do not touch the support.
If the fan rotates freely:
- Check the battery recharge system and the main fuse.
Thermoswitch operation check:

- Remove the front shield.
- Remove the thermoswitch «1».
- Connect a tester «2» (set as ohmmeter) to the
thermoswitch «1» as shown in the figure.
- Immerse the thermoswitch in a container «3» with
coolant.
In the same container, immerse a thermometer
«4» with a temperature range of 0°÷150° (32°
÷302°F).
- Place the container on a stove «5» and warm up
the coolant slowly.
- Check that the temperature indicated on the ther-
mometer and the thermoswitch value indicated on
the tester correspond to the data on the table.
COOLANT TEMPERATURE °C (°F) / RESISTANCE VALUES (OHM)

Less than 90° (194°) Unlimited
More than 90° (194°) 0
COOL SYS - 235

Coolant replacement
Emptying
- Remove the right side fairing.
- Remove the right lower spoiler.
- Unscrew and remove the expansion tank cap.
- Slide off the sleeve after loosening the clamp.
- Let the coolant drain into a container of adequate
capacity.
Filling
- Connect the sleeve and fix it with the clamp.
- Open the bleed valve.
- Fill the coolant from the expansion tank.
- Once the coolant drains out of the bleed valve
without air bubbles, close the screw, close the ex-
pansion tank, start the scooter and warm it up.
- Wait for the engine to cool down.

- Carry out the bleed operation again, inside the expansion tank, if the coolant has not reached the level
indicated.
- Restore the level in the expansion tank.
Thermostat
Removal

- Remove the side spoiler.
- Empty the cooling circuit.
- Remove the thermostat cover.
COOL SYS - 236

- Slide the thermostat off the cover.
Check
- Visually check that the thermostat is not dam-

aged.
- Prepare a metal container with approx. 1 litre of
water.
- Immerse the thermostat, keeping it in the centre
of the container.
- Immerse the multimeter temperature probe, near
the thermostat.
- Warm up the container using the heat gun.
- Check the temperature when the thermostat
starts to open:
- Warm up until the thermostat opens completely.
- Replace the thermostat if it does not work prop-
erly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.
Specific tooling
020151Y Air heater
Characteristic
Opening start temperature
85° ± 1.5°
Refitting

COOL SYS - 237

COOL SYS - 238

INDEX OF TOPICS
CHASSIS CHAS

Chassis Carnaby 125 - 200
Seat
- Remove the cover by undoing the two screws.
- Operating on both sides, undo the four screws

and remove the spark plug inspection cover pulling
it upwards.
- With the saddle opened, remove the cotter pin.
- Take out the pin with a punch.
CHAS - 240

Carnaby 125 - 200 Chassis
Rear rack
- Undo the five fixing screws.

- Remove the rear-view mirrors.
- Remove the four frame fixing screws from both
sides, as shown in the figure.
Instrument panel

- Disconnect the connectors.
- Remove the odometer cable.
- Remove the three screws shown in the figure.
- Remove the instrument panel
CHAS - 241

Front handlebar cover
- Operating on both sides of the scooter, remove

the two inspection covers of the brake calliper res-
ervoir «A».
- Undo the two screws «B».
- Remove the five screws «C».
- Remove the right and left controls assembly.

- Undo the two screws «D» and remove the front
handlebar cover.
CAUTION
OPERATE VERY CAREFULLY TO AVOID DAMAGING THE
PLASTIC PARTS
CHAS - 242

Headlight assy.
- Undo the four screws «A» and remove the front

case «B».
- Undo the screw «C» and remove the cover to

reach the expansion tank cap.

eight screws «D».
CHAS - 243


six screws «E».
- Undo the two screws «F» connecting the head-

light assembly to the turn indicators.
- Undo the six screws «G» connecting the headlight assembly to the legshield and remove the headlight
assembly.
Legshield
WARNING
CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.
WARNING
DETACH THE BATTERY POLES.
- Undo the four screws «A» and remove the radi-
ator cover «B».
CHAS - 244

- Undo the screws fixing the legshield to the frame

above the bag hook.
- Undo the screw «C» and remove the cover to

reach the expansion tank cap.
- Unscrew the expansion tank cap.

eight screws «D».

six screws «E» and remove the legshield.
CHAS - 245

Knee-guard

- Undo the screws of the cover of the expansion
tank compartment and remove the cap.
- Undo the screw of the bag hook.
- Operating from both sides, undo the eight fixing

screws.
- Slide off the shield back plate from the bottom.
Removing the ignition key-switch when on *off*
- Remove the shield back plate.

- Detach the electrical wiring.
- Remove the ignition key switch, by removing the
retaining spring as shown in the figure.
- Lightly push the master-cylinder and extract the

lock from the notch shown in the figure.
- Hence extract the master-cylinder complete with
the key-switch.
- To refit, proceed in the reverse order.
CHAS - 246

Removing the ignition key-switch when on *lock*
In position "Lock", it is not possible to access the

cylinder retaining spring. The spring must then be
removed as shown in the figure, allowing the lock
spring to be pressed out.
N.B.
TO REFIT THIS ITEM, THE SCOOTER STEERING LOCK
MUST BE RELEASED WITH THE LOCK BODY (INTERNAL
AND EXTERNAL PART) IN POSITION "OFF". PROCEED AS
DESCRIBED IN THE PREVIOUS PARAGRAPH.
See also
Removing the ignition key-switch when on *off*
Front wheel housing
- The front wheel housing is divided in two parts.

Two different procedures must be carried out to
remove it.
- Lower part:
- Remove the lower spoilers.
- Remove the four screws connecting the lower
part to the legshield.
- Upper part:
- Remove the lower part.
- Remove the legshield.
- Remove the fork
- Remove the two screws fixing the upper part to the frame.
Taillight assy.
The rear light unit has two parts that can be re-
moved separately. The operations described refer
to one part but apply to both.
CHAS - 247

- Lift the saddle and remove the three screws

«A» fixing the tail light fairing B».
- Operating on both sides, undo the screw inside

the rear wheel housing «C» and disconnect the
connector.
- Undo the two screws «D».
Footrest
- Remove the side fairings.

- Remove the cover and take out the battery.
- Remove the fuse box by pulling it upwards.
- Remove the battery lower support.
- Undo the two screws connecting the battery to
the frame.
CHAS - 248

- Undo the four centre screws.
- Operating on both sides, undo the two screws on

the lower part.
Side fairings
- Remove the cover by undoing the two screws.
- Operating on both sides, undo the four screws

and remove the spark plug inspection cover pulling
it upwards.
CHAS - 249

- Remove the luggage rack.

- Remove the upper fairing of the rear light unit by
undoing the three screws indicated.
- Undo the two screws indicated.
- Unfold the passenger footrest and undo the two

screws.
- Undo the screw indicated, inside the spark plug

inspection compartment.
- Remove the side fairing.
CHAS - 250

Rear mudguard
- Undo the two screws « A» under the air filter.
- Undo the two screws «B» and the screw «C»

supporting the fuel supply bracket.
- Unscrew the shock absorber lower clamp and

rotate the shock absorber towards the scooter rear
part.
- Remove the mudguard.
Helmet bay
- Remove the side fairings.

- Remove the luggage rack.
- Remove the upper fairing of the rear light assem-
bly.
- Operating on both sides, undo the screws indi-
cated connecting the helmet compartment to the
tank.
CHAS - 251

- Undo the screws fixing the helmet compartment

to the frame.
- Undo the screws fixing the saddle lock.
- Undo the fuel tank cap, remove the rubber fuel

recovery tank and disconnect the bleed pipe.
- Remove the helmet compartment by pulling it upwards.
spoiler
- The lower spoiler is divided into two parts that can

be removed separately. The operations described
refer to one part but apply to both.
- Remove the lower centre screw and the external
screw.
CHAS - 252

- Remove the external screw and the spoiler.
Fuel tank

N.B.
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
- Undo the two screws, on the rear wheel housing,
connecting the tank to the frame and collect the
washer.
- Disconnect the connector of the probe checking

fuel level.
- Disconnect the overflow pipe.
CHAS - 253

- Disconnect the fuel hose.

N.B.
THIS OPERATION SHOULD PREFERABLY BE PER-
FORMED WITH THE TANK EMPTY.
Front mudguard
- Undo the three screws fixing the front mudguard

to the fork plate inside the mudguard.
- Remove the mudguard.
Radiator fan

- Remove the radiator cover and disconnect the
headlight assembly connectors.
- Prepare a container to collect the coolant.
- Disconnect the delivery and return hoses of the
expansion tank.
- Disconnect the delivery and return hoses from
the radiator.
- Disconnect the connectors of the water temper-
ature sensor and the electric fan.
CHAS - 254

- Undo the screw fixing the radiator to the frame.
- Detach the radiator and the electric fan.

- Once refitted, bleed the cooling system.
Expansion tank

- Remove the radiator cover and disconnect the
headlight assembly connectors.
- Prepare a container to collect the coolant.
- Disconnect the delivery and return hoses of the
expansion tank.
- Undo the two screws and remove the expansion
tank.
Radiator cover
- Undo the four screws indicated.
CHAS - 255

INDEX OF TOPICS
PRE-DELIVERY PRE DE

Carnaby 125 - 200 Pre-delivery
Carry out the listed tests before delivering the vehicle.

Warning- be very careful when handling fuel.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection

Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
PRE DE - 257

Pre-delivery Carnaby 125 - 200
- Horn
- Starter
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN-
SURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 258

Carnaby 125 - 200 Pre-delivery
- Abnormal noise
Static test
Static control after the test ride:

- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:

Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 259

INDEX OF TOPICS
TIME TIME

Carnaby 125 - 200 Time
Engine
ENGINE
Code Action Duration
1 001001 Engine from frame - Removal and re-
fit.
2 003064 Engine oil - Change
3 003057 Engine retainer - Tighten nuts
TIME - 261

Time Carnaby 125 - 200
Crankcase
CRANKCASE
1 001153 Crankcase halves gasket - Replace-
ment
2 001133 Engine crankcase - Replacement
TIME - 262

Crankshaft
CRANKSHAFT
1 001099 Oil seal, flywheel side - Replacement
2 001117 Crankshaft - Replacement
TIME - 263

Cylinder assy.
CYLINDER- PISTON
1 001002 Cylinder-Piston - Replacement
2 001154 Pin ring piston unit - Service
TIME - 264

Cylinder head assy.
VALVE HEAD
1 001126 Head - Replacement
2 001045 Valves - Replacement
3 001049 Valves - Adjustment
4 001056 Head gasket - Replacement
5 001083 Thermistor - Replacement
6 001057 Thermostat - Replacement
TIME - 265

Rocker arms support assy.
CAMSHAFT - ROCKING LEVERS

1 001148 Valve rocking levers - Replacement
2 001044 Camshaft - Replacement
TIME - 266

Cylinder head cover
HEAD COVER
1 001093 Spark plug - Replacement
2 001089 Head cover - Replacement
3 001088 Head cover gasket - Replacement
4 001074 Oil vapour recovery pipe - Replace-
ment
TIME - 267

Chain tensioner
CHAIN TIGHTENER
1 001129 Chain tensioner - Service and Re-
placement
2 001124 By pass lubrication - Replacement
TIME - 268

Oil filter
OIL FILTER
1 001123 Oil filter - Replacement
2 001160 Oil pressure sensor - Replacement
TIME - 269

Driven pulley
DRIVEN PULLEY
1 001022 Clutch - Replacement
2 003072 Clutch unit - Wear check
3 001012 Driven pulley - Service
4 001110 Driven pulley - Replacement
5 001155 Clutch bell housing - Replacement
TIME - 270

Oil pump
PUMP - OIL SUMP UNIT

1 001125 Chain guide pads - Replacement
2 001051 Belt/ Timing chain - Replacement
3 001042 Oil pump - Service
4 001112 Oil pump - Replacement
5 001122 Oil pump chain - Replacement
6 001121 Chain cover oil seal - Replacement
7 001130 Oil sump - Replacement
TIME - 271

Final gear assy.
FINAL DRIVE
1 001010 Gear reduction unit - Inspection
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gear box oil - Replacement
4 004125 Rear wheel axle - Replacement
TIME - 272

Driving pulley
REAR-VIEW PULLEY
1 001086 rear-view half-pulley - Replacement
2 001011 Driving belt - Replacement
3 001066 Driving pulley - Removal and Refit-
ting
4 001006 driving pulley - Service
TIME - 273

Transmission cover
TRANSMISSION COVER
1 001135 Transmission cover bearing - Re-
placement
2 001096 Transmission crankcase cover - re-
place
3 001131 Transmission air intake - Replace-
ment
Flywheel magneto
MAGNETO FLYWHEEL AND SECONDARY AIR

1 001087 Flywheel cover - Replacement
2 001113 Water pump - Replacement
3 001058 Flywheel - Replacement
4 001173 Rotor - Replacement
5 001067 Stator - Replacement
TIME - 274


6 001161 Secondary air filters - Replacement /
Cleaning
7 001162 Secondary air housing - Replace-
ment
8 001174 SAS valve - Replacement
9 001163 SAS valve / Head connection - Re-
placement
Carburettor
CARBURETTOR
1 001013 Intake manifold - Replacement
2 007020 Carburettor heat. pipes - Replace-
ment
3 001008 Carburettor - Inspection
4 001063 Carburettor - Replacement
5 001081 Automatic choke - Replacement
6 003058 Carburettor - Adjustment
7 001136 Exhaust emissions - Adjustment
TIME - 275

Exhaust pipe
MUFFLER
1 001009 Muffler - Replacement
2 001095 Muffler guard - Replacement
3 001092 Exhaust manifold - Replacement
TIME - 276

Air cleaner
AIR CLEANER
1 001014 Air filter - Replacement/Cleaning
2 001015 Air filter box - Replacement
3 004122 Carburettor air cleaner attachment -
Replacement
TIME - 277

Frame
CHASSIS
1 004001 Chassis - Replacement
TIME - 278

Centre-stand
CENTRE AND SIDE STANDS

1 004004 Stand - Replacement
TIME - 279

Legshield spoiler
LEGSHIELD - SPOILER
1 004064 Legshield - Replacement
2 004053 Spoiler - Replacement
TIME - 280

Side fairings
SIDE COVERS
1 004085 Fairing (1) - Replacement
2 004012 Rear side panels - Replacement
3 004052 Bumper - Replacement
TIME - 281

Footrests
MATS AND COVERS

1 004075 Front mat - Replacement
2 004079 Passenger footrest (1) - Replace-
ment
3 004015 Footrests - Remov. and Refit.
TIME - 282

Rear cover
REAR SHIELD
1 004065 Legshield rear section - Remov. and
Refit.
TIME - 283

Central cover
CENTRAL COVER
1 004011 Frame central cover - Replacement
2 002082 Fuel tank cap opening drive - Re-
placement
TIME - 284

Underseat compartment
HELMET COMPARTMENT- SEAT ELECTRIC OPENING-LICENCE PLATE HOLDER

1 002083 Saddle opening transmission - Re-
placement Saddle opening transmis-
sion - Replacement
2 004016 Helmet compartment - Remov. and
Refit.
3 004106 Underseat band - Replacement
4 004136 License plate holder support - Re-
placement
5 004158 Saddle opening splitter - Replace-
ment
6 005046 Battery cover - Replacement
7 005099 Electric saddle opening activator -
Replacement
TIME - 285

Mudguard
FRONT AND REAR MUDGUARDS

1 004009 Rear mudguard - Replacement
2 004002 Front mudguard - Replacement
TIME - 286

Fuel tank
FUEL TANK
1 005010 Tank float - Replacement
2 004109 Fuel tank breather - Replacement
3 004005 Fuel tank - Replacement
4 004007 Fuel valve - Replacement
TIME - 287

Expansion tank
EXPANSION TANK
1 007001 Expansion tank - Replacement
2 007013 Expansion tank - radiator connection
pipe - Replacement
3 001052 Coolant and air bleeding - Replace-
ment
TIME - 288

Radiator
RADIATOR
1 007014 Radiator thermal switch - Replace-
ment
2 007002 Radiator water - Replacement
3 007016 Complete fan with support - Replace-
ment
4 007003 Coolant delivery and return pipe - Re-
placement
TIME - 289

Rear shock-absorber
REAR SHOCK ABSORBER

1 003007 Rear shock absorber - Remov. and
Refit.
TIME - 290

Steering column bearings
STEERING FIFTH WHEELS

1 003051 Fork unit - Replacement
2 003079 Fork stem - Replacement
3 003048 Fork oil seal - Replacement
4 004119 Bearing/upper steering fifth wheel -
Replacement
5 003002 Steering fifth wheel - Replacement
6 003073 Steering clearance - Adjustment
7 003010 Front suspension - Service
8 003050 Fork lower plate - Replacement
9 003076 Fork sheath - Replacement
TIME - 291

Handlebar covers
HANDLEBAR COVER
1 004018 Handlebar front section - Replace-
ment
2 004019 Handlebar rear section - Replace-
ment
TIME - 292

Handlebar components
HANDLEBAR COMPONENTS
1 002060 Throttle grip - Replacement
2 002037 Brake or clutch lever - Replacement
3 002071 Left knob - Replacement
4 002024 Front brake pump - Removal and Re-
fitting
5 002067 Rear brake pump - Replacement
6 003001 Handlebar - Replacement
7 002063 Complete throttle grip transmission -
Replacement
8 002059 Right-hand knob - Replacement
9 003061 Accelerator transmission - Adjust-
ment
10 005017 Stop switch - Replacement
TIME - 293

Swing-arm
SWINGING ARM
1 001072 Swinging arm - Engine-chassis con-
nection - Replacement
2 004058 Silent block - Replacement
TIME - 294

Brake hoses
BRAKE PIPING
1 002039 Front brake calliper - Replacement
2 002040 Front brake calliper - Service
3 002021 Front brake piping - Replacement
4 002047 Front brake fluid and system bleed-
ing plug - Repl.
5 003070 Front brake pads/shoes - Check for
wear
6 003071 Rear brake pads/shoes - Check for
wear
7 002002 Rear brake pads/shoes - Repl.
8 002007 Front brake pads/shoes - Remov.
and Refit.
9 002048 Rear brake calliper - Replacement
10 002020 Rear brake hose - Remov. and Refit.
11 002080 Rear brake oil bleeding system - Re-
placement
12 002081 Rear brake rigid pipes - Replacement
TIME - 295

Seat
SADDLE
1 004003 Saddle - Replacement
TIME - 296

Seat lock
SADDLE LOCK MECHANISM

1 004054 Saddle lock catch - Replacement
TIME - 297

Instrument panel
INSTRUMENT PANEL
1 005014 Odometer - Replacement
2 005038 Instrument panel warning light bulbs
- Replacement
TIME - 298

Rear rack
LUGGAGE RACK
1 004008 Luggage rack - Replacement
TIME - 299

Locks
LOCKS
1 005016 Key switch - Replacement
2 004010 Anti-theft lock - Replacement
TIME - 300

Turn signal lights
TURN INDICATOR LIGHTS

1 005002 Front headlamp - Replacement
2 005005 Taillight - Replacement
3 005008 Headlight bulbs - Replacement
4 005031 Licence plate light bulb - Replace-
ment
5 005032 Licence plate light glass - Replace-
ment
6 005044 Front lights cable unit - replace
7 005066 Rear light bulbs - Replacement
8 005067 Front turn indicator light - Replace-
ment
9 005068 Rear turn indicator bulb - Replace-
ment
TIME - 301

Front wheel
FRONT WHEEL
1 002041 Brake disc - Replacement
2 003037 Front wheel rim - Remov. and Refit.
3 003038 Front wheel axle - Remov. and Refit.
4 003040 Front wheel bearings - Replacement
5 003047 Front tyre - Replacement
6 003063 Tyre pressure - Check
7 004123 Front wheel - Replacement
8 002011 Odometer drive - Replacement
9 002049 Odometer cable - Replacement
10 002051 Odometer transmission assembly -
Replacement
Grease tone wheel or drive

Please take note that the code has been intro-
duced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sen-
sor replacement) and 005089 (tone wheel replace-
ment) in the event of noise of the indicated
components.
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 302

AGIP GREASE SM 2 Grease for the tone wheel

revolving ring
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Rear wheel
REAR WHEEL
1 001016 Rear wheel - Replacement
2 001071 Rear wheel rim - Removal and Refit-
ting
3 002070 Rear brake disc - Replacement
4 003063 Tyre pressure - Check
5 003077 muffler/rear shock absorber support
arm - Service
6 004126 Rear wheel tyre - Replacement
TIME - 303

Electric start
ELECTRICAL START-UP
1 001020 Starter motor - Replacement
2 001017 Start-up pinion - Replacement
TIME - 304

Fuel pump
FUEL PUMP
1 004073 Fuel pump - Replacement
2 004137 Carburettor pump hose - Replace-
ment
3 004089 Tank-pump hose - Replacement
4 004072 Fuel filter - Replacement
TIME - 305

Electric devices
TIME - 306

ELECTRIC DEVICES
1 001023 Control unit - Replacement
2 001069 HV coil - Replacement
3 001094 Spark plug hood - Replacement
4 005001 Electrical system - Replacement
5 005003 Horn - Replacement
6 005035 Headlight remote control - Replace-
ment
7 005052 Fuse (1) - Replacement
8 005054 Fuse block (1) - Replacement
9 005114 Electrical system - Service
TIME - 307

Secondary air box
SECONDARY AIR HOUSING

1 001162 Secondary air housing - Replace-
ment
2 001161 Secondary air filter - Replacement /
Cleaning
3 001174 SAS valve - Replacement
4 001163 SAS valve / Head connection - Re-
placement
5 001164 Crankcase secondary air connection
- Replacement
TIME - 308

A
Air filter: 47
B
Battery: 60, 76, 90
Brake: 218, 219, 222, 223, 225, 226, 229, 230, 295
C
Carburettor: 13, 42, 173, 181, 275
Coolant: 236
E
Engine oil: 48
Engine stop:
F
Fuel: 59, 172, 253, 287, 305
Fuses: 89
H
Headlight: 54, 243
Hub oil: 46
I
Identification: 8
Instrument panel: 241, 298
L
Luggage rack:
M
Maintenance: 7, 39
O
Oil filter: 49, 269
S
Saddle:
Shock absorbers: 212
Spark plug: 44, 82
Start-up:
T
Tank: 253, 255, 287, 288
Transmission: 10, 60, 100, 120, 274

Tyres: 11

Carnaby 125 Service Manual

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SERVICE STATION MANUAL

633986 IT-633987 EN-633988 FR-633989 DE-633990

Carnaby 125 - 200

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ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

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The chassis prefix «A» is located near the right

The engine prefix «B» is stamped near the left

VEHICLE IDENTIFICATION 125

VEHICLE IDENTIFICATION 200

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Dimensions and mass

WEIGHTS AND DIMENSIONS 125

WEIGHTS AND DIMENSIONS 200

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ELECTRICAL SYSTEM 125

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ELECTRICAL SYSTEM 200

Frame and suspensions

CHASSIS AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

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CRANKCASE AND CRANKSHAFT

(°) Apply LOCTITE 242 medium-strength threadlock

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Cylinder - piston assy.

COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)

COUPLING CATEGORIES (WITH CAST IRON CYLINDER)

125 cm³ version

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ENGINE SEALING RINGS

ENGINE SEALING RINGS (1ST OVERSIZE)

ENGINE SEALING RINGS (2ND OVERSIZE)

ENGINE SEALING RINGS (3RD OVERSIZE)

200 cm³ version

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ENGINE SEALING RINGS

Crankcase - crankshaft - connecting rod

CRANKCASE - CRANKSHAFT COUPLINGS

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CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Slot packing system

MODELS WITH FIBRE HEAD GASKET (1.1)

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Name Measure A Thickness

MODELS WITH METAL HEAD GASKET (0.3)

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RECOMMENDED PRODUCTS TABLE